Henan Jingxin Fabric Technology Co., Ltd. is a national-level high-tech enterprise. We are professional manufacturer for Paper Machine Clothing (PMC) such as Triple layer Forming Fabric (SSB), double warp flat filament dryer screen, Spiral dryer screen etc. We hold the belief that, High quality products originated from the best raw materials, the most advanced machine and the hard endeavour teams. We are using Germany Perlon® Filament only, and we owned the most advanced Germany Jurgens® 16 meters looms, Sweden TEXO® automatic rapier looms, Austria WIS® automatic Seaming machine and notching machine, Germany Schlatter® Jagar warping machine and Schlatter® 15 Meters heat setting machine, achieved an annual production capacity of 1 million square meters with the output value of 50 million US dollars. We have successively passed ISO9001, ISO14001, ISO45001 certification and have more than 10 years cooperation with China Top10 paper making corporations and many famous paper making corporations across the world.
HENAN JINGXIN FABRIC TECHNOLOGY CO., LTD
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：+86 394 5228866 : 0086 18838386818 ：+86 394 5106388 ：info@jingxincorp.com ：www.jingxincorp.com
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ALLIANCE INTERNATIONAL Sales / Service Agents
SOLUTIONS for the PULP & PAPER
Alliance International is a leading supplier of consumables, components, assemblies and new and used paper machinery. We represent wellknown manufacturers in the pulp and paper industry who are known for their quality and reliable products. This enables us to provide cost effective solutions to the pulp & paper industry.
INDUSTRY
STOCK PREPARATION • Drum Pulper • Centri Cleaners • High Pressure Screens • Baskets Slotted / Perforated • Screw Press • Hot Disperser • Poly Disc Filter(PDF) • Chest Agitators PRESS & DRYER PART • Press Felts • Dryer Fabrics • C. I. Dryers / MG • C. I. Press Rolls • C. I. Pope Reel Drum • Granite Rolls • Suction Press Rolls • Calendar & Calendar Rolls • Pocket Ventilation & Hood • Online Felt / Screen Cleaners
PAPER MACHINE • Forming Fabrics • Head Box- Pressurised • Suction Boxes & Ceramic Covers • Suction Couch Rolls • Doctor Blades & Systems • Shower System & Nozzles • Vaccum Pumps FINISHING HOUSE • Rewinder • Simplex Sheeter • Reel Handling System • Complete Warehousing Solutions (ASRS)
ALLIANCE INTERNATIONAL
WORLD’S LARGEST PAPER SHOW
Stall No-D04 | Hall No-10 10-13 May | 2022 | India Expo Centre,
Greater Noida, Delhi-NCR, India G-32, Suite No. 201, Hansraj Sethi Marg, New Delhi-110019 (INDIA) • Ph.: 011-41315501/02/03 • Fax : 011-41315506 • Mob.: +91 9810102608 • E-mail : aneja@allianceint.co, info@allianceint.co • Website: www.alliancepapermachinery.com
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SHEETER
CONTENTS February-March, 2022, Paper Mart
Paper Boat Needs WATER to Float… Save it! 14
ITC: 70 Percent of Water Discharge Used by Farmers for Irrigation Purposes
TNPL: Launched 122 Projects to Save About 34.50 million m3 of Water Per Year
Naini Papers: Developing Holistic Approach to Water Management
Trident: Invested 20 Cr. to Ensure Increased Water Storage Capacity & Reduced Groundwater Abstraction
Kuantum Papers: Implemented Water Conservation Measures to Reduce Consumption by 2500 m3/day
Star Paper Mills: Reusing Treated Water in Cooling, Sealing, Cleaning, Gardening and Fire Hydrants
Emami Paper Mills: Adopting the Principle of ‘Reduce, Reuse, Recycle and Recover’
Shreyans Industries: Encouraging Proper Wastewater Management
BILT Graphic Paper Products: Installing Best Technology for Recycling of Water within Production Process
N R Agarwal Industries: Recovering 2300 m3 Water per day through Tertiary Treatment in the form of RO
Yash Pakka: Our Goal is to Reduce Water Consumption to 25 m3/MT
Silverton Pulp and Paper: Installed Fiber Recovery Cells to Clarify Wastewater
Sukraft: Ensuring Zero Liquid Discharge at All Units
EVENT COVERAGE
84 IPPTA holds 56th AGM & Seminar Emphasising on Best Practices in the Industry
GETTING GREENER Forestry Practices of Paper Mills
48
74
78 ITC PSPD: Embarking upon Digital Transformation to Achieve Bottom-Line Benefits & Operational Excellence
‘We are unique in the paper packaging and print field in the manner in which we identify a new opportunity, do a deep dive, assess the worth, assemble a team and then create prototypes and deliver a product which very often creates a new market or adds value by substitution.’
‘We are constantly exploring opportunities to add capacities in the current machines and through new machines at our factories.’
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98
Cheema Boilers: Steaming Ahead to Make Industry Energy Efficient
Proklean Technologies – Driven by Cost-effectiveness & Sustainability ‘We are completely committed to coming up with a wide range of products for the pulp and paper industry... reducing the pollution footprint of the industry and also helping the industry to save costs.’
Pidilite Industries: Strengthening Position in Paper Coloration Products ‘We are a market leader in colorants for writing & printing paper and board manufacturing. This stems from our technological understanding of pigment and dispersion technology, backward integration and ability to work closely with customers for specific developments.’
‘In view of the rising energy demand and related environmental concerns, the paper industry is gradually moving towards alternate and more efficient fuel options. Foreseeing the future, Cheema Boilers Ltd. is continuously upgrading itself technologically.’
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Innovation is the Growth Mantra of ITC-PSPD
PRODUCT WATCH
108
NEWS
119
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PAPER Boat Needs WATER
to Float… Save it!
14 | www.papermart.in / February-March, 2022
S
urrounded by myths, the paper Industry is often hailed as ‘not good for the environment.’ However, in reality, paper is one of the very few truly sustainable products. Made from wood, agricultural residue, or waste paper, it is – renewable, reusable, and recyclable. The manufacturing process is also becoming environment-friendly with the changing times. Gone are the days when the industries used to release untreated water into rivers and streams. Today, not just paper, but every industry is doing its bit to make the world a better place to live and technology is playing a vital role in it. The paper industry is one of the highest consumers of water. From digesting wood chips to making fiber slurry, water is required in almost every process of pulp and paper manufacturing. While water consumption patterns and effluent discharges may vary substantially from mill to mill owing to the kind of raw materials used, there lies an opportunity for every mill to do things in a smarter and sustainable way.
Water Conservation Practices in Paper Mills Some of the initiatives taken by the mills are recirculation of freshwater, use of highly efficient imported vacuum pumps and reverse osmosis systems, rainwater harvesting, utilisation of treated effluent water for irrigation, and more. In a recently held seminar at the 56th AGM of Indian Pulp & Paper Technical Association (IPPTA), Dr. Ashok Kumar, Executive Director, Pudumjee Paper Mills, showed how mills are taking steps towards sustainability, through his presentation which indicated that the water usage in 2012-13 has reduced to 68 m3 per BDMT of product from 250 m3 per BDMT in 1995-1996. Meanwhile, there has been a significant reduction in COD, BOD, and TSS in the effluent treatment plant. However, Dr. Kumar pointed out that in the near future, groundwater extraction may be further restricted and environmental discharge and emission norms may be further tightened. Hence, in order to keep up with the changing trends, the industry needs a holistic and multi-dimensional approach including process optimisation, adoption of best practices, and ETP upgradation. In this context, many national and international organisations such as United Nations Industrial
Development Organization (UNIDO), Central Pulp and Paper Research Institute (CPPRI), and paper associations have joined hands to introduce the best available technologies and facilitate the adoption of global best practices at paper mills.
Espousing a Multi-faceted Approach for Water Sustainability Reusing and recycling water is one of the most significant ways to reduce water consumption as well as minimise wastewater discharge for any industry. Talking about the wastewater treatment infrastructure at ITC, Mr. Sanjay Singh, Group Head - Paper & Packaging, ITC Ltd., said that the company has an elaborate system for treating effluent water. “About 70 percent of the water discharged is used by the farmers for irrigation purposes,” he further informed. Meanwhile, Mr. Vivek Chawla, Whole Time Director and CEO, Emami Paper Mills Ltd. added that Emami Paper Mills has achieved the status of zero solid waste by adopting the principle of ‘Reduce, Reuse, Recycle and Recover’. In any organisation, water conservation can only be achieved if it is done collectively as a team at every process. While discussing Naini Group’s holistic approach to water management, the company’s Managing Director Mr. Pawan Agarwal revealed, “Whatever technologies we are trying to adopt at various locations – be it a new installation, upgradation, or replacement, we try to assess the water footprint of the particular equipment and see if it could bring down the present level of water consumption.” Of late, the paper mills have started investing more and more into their water treatment infrastructures. One such example is N R Agarwal Industries, which has invested around INR 37 crore in the last three years, to increase the capacity of secondary treatment and installed a new tertiary treatment system in the form of RO. Be it a wood-based pulp mill, bagasse paper mill, or waste paper based-mill, every paper mill has come forward to achieve one objective – ‘Save Water’. As we celebrate World Water Day on March 22, Paper Mart has tried to bring out the existing practices of some of India’s paper mills to provide its readers an insight into their efforts, technologies, and measures for conserving water.
www.papermart.in / February-March, 2022 | 15
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ITC: 70 Percent of Water Discharge Used by Farmers for Irrigation Purposes Our water treatment process and wastewater treatment strategies… We have a very elaborate system of measurement of water consumption at various points. It is monitored every day against the set targets. The simple rule is that managers do what management measures.
Our investment into water treatment infrastructure…
Mr. Sanjay Singh, Group Head - Paper & Packaging, ITC Ltd.
We have created a very detailed system of treating effluent water before it is discharged. We meet all the parameters of the treated effluent much better than the norms. In fact, 70 percent of the water discharged is used by the farmers for irrigation purposes. We measure the soil samples by getting them tested by the agricultural university to see if there are any effects on soil conditions or the quality of the groundwater. This has been done for more than 25 years now. No adverse effects are seen on soil conditions or groundwater quality. We have kept a fish in a tank where treated effluent is put to test the quality of water. Since fish is very sensitive to the quality of water, it acts as a test method for the quality of effluent.
Water consumed per tonne of paper produced… We use about 30 m3 of water per tonne of paper which is one of the lowest in the industry. We recycle the water internally to the maximum extent possible to reduce water usage.
Measures undertaken to minimise the consumption… We have a team that works on reducing water consumption on a continu-
16 | www.papermart.in / February-March, 2022
ous basis. It is reviewed regularly by our management committee. We are also working on treating our sewage water and using it in our cooking towers. We treat the effluent and reuse water in our pulp mill. Talking about environment management, we are the only pulp mill in the country to have ozone bleaching to reduce the impact on the environment. We were also the first ECF mill in the country. We have a system of collecting the gases from various points and burning them in the lime kiln and boiler thereby eliminating the smell.
Recent developments with regards to water management and treatment… We have recently commissioned a high-efficiency recovery boiler which will reduce coal consumption by more than a hundred thousand tonnes. We have put up a BCTMP mill with zero effluent discharge. We are also investigating a new bleach plant that will reduce chemical consumption and power and water consumption.
Path-breaking steps taken… ITC Ltd. has been running a largescale Integrated Water Stewardship programme for several decades. Aligned to the ‘Pradhan Mantri Krishi Sinchai Yojana’, the programme aims at providing access to water to support livelihoods besides creating a positive water balance through supply-side augmentation and demand-side management. ITC has recently received the first prize for water management and conservation at the third edition of the National Water Awards by the Ministry of Jal Shakti.
Ax chem Group
GO
RESPONSIBLE SUSTAINABLE AXCHEM®
Delight Your Machine With Higher Productivity AXCHEM ® has developed a new range of polymers with a complex molecular structure, to improve drainage values & machine efficiency by increasing the productivity compared to traditional Polyacrylamides. Objective: n Increased Free Drainage n Machine Speed Enhancement n Productivity Enhancement Merits Newly Developed Polymer n Reduction in Vacuum Levels n Lower Press Loads n Higher Bulk Without comprising ash n Energy saving n Strong surface bonding Working Mechanism
Case Study – A mill producing packaging grade with 100% recycled fiber, facing issue of lower drainage values & unable to increase the productivity. AXCHEM® solutions proposed newly developed polymer as a drainage booster to improve their production rate by increasing free drainage at forming section. The selected product has been positioned between the coagulant and flocculant in use without changing incumbent retention program with a dosage of 1.5 – 2.0 kg/t. The dry line on the table started shifting towards headbox & lower vacuum reading at vacuum gauges. The faster drainage of water @ the forming board encouraged production team to increase the machine speed and significant gain of 6% to 8% in paper production.
The new molecular structure is obtained by subjecting the new Polyacrylamide to strong mechanical-chemical stress forces. This causes a PAM to form smaller flocs which are more resistant to shear forces. The charge is released gradually over the fibres helping to form smaller flocs with a geometry that easily releases water at every stage of the paper forming and drying sections. The most obvious effect is the increased drainage on the forming section, better release in the press section, but importantly increased evaporation in the dryer section. Application Method
The new range of polymers proposed by ® AXCHEM enables papermakers to meet new challenges: It is a new tool to increase drainage and productivity without changing the process circuit chemistry.
n Newly developed polymers can be added to the incumbent retention program without changing the balance of chemical system.
The ease of application of this new range of polymers allows the rapid and immediate assessment of the benefits to which the mill can attain
AXCHEM has the best application specialist to support customers to improve machine efficiency ®
Axchem Solutions India Private Limited
19, JNPC, Ponnuru Village, Parawada Mandal, Visakhapatnam – 531021, Andhra Pradesh, INDIA Email: info@axchem-india.com, Website: www.axchemgroup.com
S•P•E•C•I•A•L F•E•A•T•U•R•E
TNPL: Launched 122 Projects to Save About 34.50 million m3 of Water Per Year Our water treatment process and wastewater treatment strategies…
Thiru. S. Krishnan (IAS), Chairman and Managing Director, Tamil Nadu Newsprint & Papers Ltd.
Global water use has increased by a factor of six over the past 100 years because of increasing population, economic development, and shifting consumption patterns. For businesses and industries, water stress is one of the main drivers for water reuse and efficiency improvements. Water scarcity is a seasonal phenomenon for manufacturing units like TNPL, which need a large quantity of water and are located near water-stressed areas/rivers. However, seasonal water scarcity has a huge impact on the sustainable operations of the mill throughout the year. At TNPL, we look at day-to-day operations along with water consumption and monitoring. Our water conservation measures focus on recycling and reuse of water and wastewater by identifying appropriate places and purposes with quality and quantity, better monitoring, and leak detection with the right contemporary technologies for treating water and reusing treated wastewater. This is achieved through dedicated water conservation and management team headed by the unit head and members drawn from all levels and departments. The responsibility of the team is to identify and implement water conservation, and recycling measures at both micro and macro-level and to create awareness among the employees and other stakeholders. The water treatment plant comprises all the modern treatment facilities and storage facilities like a process water reservoir, multi-grade filter to generate filtered water, pressure sand filtration, high rate solids contact
18 | www.papermart.in / February-March, 2022
clarifier, ultrafiltration reverse osmosis (RO) plant, de-mineralisation plant, etc. The present average consumption for the process is around 35,000 KLD, which includes potable water supply to nearby villages covered under CSR. Waste Water Treatment Plant The entire waste generated from the Mill is segregated and collected in two streams: 1. High BOD and Low Volume stream 2. Low BOD and High Volume stream The high BOD stream consisting of wastewater from bagasse storage yards and bagasse preparation plants is treated through a bio-methanation plant to generate biogas and used as renewable fuel at a lime kiln. Treated wastewater is further polished in anaerobic lagoons and primary clarifier before mixing with pre-treated low BOD high volume effluent stream. The low BOD and high volume stream consisting of wastewater from the pulp mill, paper machines, and soda recovery plants are treated through primary clarifiers. The overflow is mixed with partially treated effluents from high BOD treatment and subsequently treated through a secondary treatment system consisting of activated sludge lagoon, secondary clarifiers, sludge thickener (to remove secondary) sludge, etc. The overflow from secondary clarifiers is partially re-used in various plant operations and the balance is sent for tertiary treatment. Tertiary treatment by Ozone TNPL’s R&D work to control the colour from the final treated wastewater has resulted in the introduction
S•P•E•C•I•A•L F•E•A•T•U•R•E
of a colour removal system based on the ozonation process. The system was put up at a cost of around INR 4 crores. The introduction of ozone, as a tertiary treatment for the treatment of final effluent, is the ‘first of its kind’ in the Indian pulp and paper industry. Apart from the capital expenditure, the company is spending a significant amount on ozonisation. The ozone-treated wastewater having high dissolved oxygen when used for agriculture purposes would improve the soil fertility by way of mineralisation of organic matter into useful nutrients and supports plant growth by promoting a healthy root system, thereby increasing crop yield.
Our investment into water treatment infrastructure… TNPL, being a technology-driven company, invests regularly in the water treatment facility to upgrade the treatment infrastructure since its inception. The company has invested more than INR 100 crores in various water conservation projects.
Water consumed per tonne of paper produced… The current water consumption is 32 to 33 m3/MT of pulp and paper.
Measures undertaken to minimise the consumption… Our approach to water conservation, reuse & recycling is based on the ‘Circular Economy Model’ by circling more by reusing and recycling without treatment, partial treatment, and after treatment inside the mill. Finally, the remaining treated wastewater is used for irrigation purposes. Reuse the water without treatment after usage All the water used for pump cooling in various process in the plant are collected in a sump through a network of pipelines and collected water is once again pumped back to the water treatment plant as such without treatment to reduce freshwater intake.
Within the plant Water used in various processes is reused from one stage of the process to another stage in the same plant, based on the quality and quantity requirements. Recycle water from one plant to other plant • Paper machine backwater is reused for dilution of pulp in chemical or wastepaper pulp mill. • Hot water generated from the hardwood fiber line is reused in the bagasse fiber line. This saves fresh water and energy used to produce hot water. • Process condensate and vacuum pump seal water from the chemical recovery plant are reused in the pulp mill in various stages of pulp washing. Recycle after partial treatment The wastewater generated in the paper machine mostly contains suspended solids and it is treated
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through settling in the clarifier and the clarified water is reused in the backwater clarification system of the bagasse pulp plant. Similarly, the white water generated from the paper machine is filtered through a special filter and filtered water is reused for showers. Recycle after full treatment Wastewater, after treatment in the effluent treatment plant, is reused in the bagasse yard.
Recent developments with regards to water management and treatment… TNPL has managed the water shortage in River Cauvery by reducing freshwater consumption through extensive reuse and recycling of processes and wastewater by implementing various plans. A number of water conservation measures have been undertaken to manage the water crisis. There are about 122 projects taken up by which about 10 million m3 of water has been saved. The water savings
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due to these water conservation projects is about 34.50 million cubic meters per year. Case Study 1: Return of pump seal water and hydraulic oil cooling water in Hardwood Street to water treatment plant. Freshwater used for all the pump seals in the digester, bleaching, and other areas of hardwood fiber line was drained to the effluent channel and wasted. It also increases the hydraulic load in the effluent stream. A project was conceived to collect all pump seal water by laying a network of pipelines and channeling it to two collection pits (based on the fiber line floor topography). All pumps seal water collected in the collection pit was pumped to an existing water storage tank. From there, it is pumped to the water treatment plant and used as a freshwater source. Level controllers and conductivity meters were installed in collection pits and storage tanks to have better control over pumping and water quality. The freshwater saving is about 300 m3/day. Case Study 2: Recycling Paper Machine effluent after clarification for bagasse washing and storage. Freshwater/treated effluent was used in the bagasse handling and storage area. Paper machine wastewater, which contains relatively low TDS, was identified as an alternative to freshwater/treated effluent. It was clarified using one of the clarifiers separately and pumped to bagasse handling and storage area for use. This has reduced average freshwater consumption by 4000 m3 per day and TDS entry to process from treated wastewater.
Path-breaking steps taken… A Circular Economy is a regenerative system in which resource input, waste, and emission are minimised by closing and narrowing energy & material loops. This can be achieved by reducing, recycling, reusing, refurbishing, and recovering resource
input used for manufacturing and by minimising wastes and emissions. This is in contrast to a linear economy which is based on the ‘take, make, dispose’ model of manufacturing and use. TNPL voluntarily made many initiations and is a pioneer in achieving the circular economy models in the various manufacturing process and this helps TNPL to function as an economically and environmentally sustainable company among integrated pulp and paper industries across the globe. A few of the examples of the circular economy concept adopted in the mill are: • Biogas from Bagasse wash wastewater: Earlier, bagasse wash wastewater was treated in the open anaerobic lagoon to reduce the organic load carryover and energy consumption in the activated sludge process. Biogas generated from the anaerobic lagoon, due to uncontrolled anaerobic digestion of organic compounds present in the wastewater was emitted into the atmosphere. It is known that biogas contains nearly 75 percent methane, the second-largest greenhouse gas, next to CO2 , and has 25 times more global warming potential than CO2 . Commissioning of bio-methanation plant process, anaerobic digestion of bagasse wash wastewater is being done in the closed reactor that makes it possible to capture generated biogas of around 27000 to 30,000 cubic meter per day and use as in house renewable energy, in lime kiln and this prevents uncontrolled methane emission to atmosphere from anaerobic lagoon. The use of biogas in lime kiln resulted in a saving of around 15-18 KL of furnace oil saving leading to a cut down of CO2 emission from fossil fuels to the atmosphere. Together, about 95,000 to 1,00,000 MT CO2e GHG emissions are reduced per annum. • Utilisation of Lime sludge and Fly ash for Cement manufacture: The lime sludge generated during the first stage causticizing process
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in the chemical recovery cycle and the fly ash generated from the power boilers, lime grits, grits from PCC & GCC plant, bed ash rejects & colour coating kitchen sludge from TNPL unit 2 are issues of concern in inorganic solid waste management. An innovative solution was evolved by combining these two inorganic solid wastes and converting them into high-grade cement. Initially, a 600 TPD plant was put up in the mill and the project was commissioned in 2012. This project is a beacon for other mills, in the direction of converting wastes into wealth besides addressing the concerns being faced in the disposal of inorganic solid wastes. Further, the plant has undergone expansion from 600 TPD to 900 TPD in the year 2015. Further, the CO2 present in the flue gas from the cement manufacturing process is utilised for the production of PCC. • Recovery of Caustic soda lye during paper machine boil out: Wet end area and associated pulp chests in the paper machines are frequently washed and cleaned by caustic boil out to keep the system clean and to reduce the problem associated with deposits and slime growth. Wastewater generated during the caustic boil out contains a high concentration of sodium hydroxide, which is detrimental to the environment as well as to the effluent treatment process. To avoid this, caustic boil-out wastewater is being separately collected stored in the tanks and reused in the soda recovery plant and also to reduce the caustic make-up. • Wastewater reuse: The wastewater generated in the paper machines is treated by clarifier and reused in the backwater system at the chemical bagasse plant. Process condensate and vacuum pump seal water from the soda recovery plant is reused in the pulp mill in various stages. • Bio-fuels: Waste pith generated from bagasse and wood dust from wood chipping are fired in the boiler to replace the fossil fuel and to reduce GHG emissions.
We are Specialists in Dryer Section Deposit Prevention Maintech Supplies a Total Solution for Problems Created by Dryer Section Deposition. After Conducting a Dryer Section Audit, We Work Closely with Customers to Prevent Deposition and its Impact on Runnability, Production Rate and Quality. DRYER CYLINDER SURFACE PASSIVATION BEFORE
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Channel Partner for Indian Market
Marubeni India Private Limited Unit No.01, 3rd Floor, Building A-2, Shaheed Jeet Singh Marg, Qutab Institutional Area, New Delhi-110067, India E-MAIL: Shashank-S@marubeni.com | MOB: +91-9672308030 TEL: +91-11-41295555 | FAX: +91-11-41295585
www.maintech-papertech.com
S•P•E•C•I•A•L F•E•A•T•U•R•E
Naini Papers: Developing Holistic Approach to Water Management
Mr. Pawan Agarwal, Managing Director, Naini Papers Ltd.
Our water treatment process and wastewater treatment strategies…
tion. And, we have been able to do all this successfully. We have adopted a multi-pronged approach.
Water conservation is the need of the hour. Every industry which is consuming water has to be conscious of the fact that water is a very precious commodity that needs to be conserved for the future generation. So, keeping this view in mind, we are trying our best to preserve water at each and every point of consumption.
Our investment into water treatment infrastructure…
We have reduced the freshwater consumption at all points by replacing it with the backwater. We are also trying to recycle the backwater but facing some issues due to high TSS and TDS. For instance, if we add certain kinds of filters to reduce the TSS, there is an issue with the DTSM colour. Therefore, we are adopting various treatment processes, depending upon the quality of the backwater. Then, we are trying to do some kind of pre-treatment, review chemical treatment, and then, reduce the colour, thereby making it suitable for reuse. Thus, we are trying to use maximum backwater and minimum freshwater at various points of consumption. We have the technologies available to reduce that water demand. For example, in the machine section, there is a section called the wire part – the forming section, where we have a lot of showers – high-pressure and low-pressure showers - the purpose of which is to keep the fabric clean. Now, we have installed an ultra-high-pressure shower, which operates at the pressure of 120 bar, and has a very small-sized nozzle – just 0.2 mm instead of 1 mm. As compared to conventional showers, the water consumption is very low - hardly 25 to 30 percent. Likewise, we are trying to save water at various points of consump-
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Naini Group, over a period of time, has invested considerably in stateof-the-art technologies for both its companies, viz. Naini Papers Ltd. and Naini Tissues Ltd. to improve environmental performance. We have recently purchased fiberline from Valmet worth INR 400 crores which is water and energy-efficient. Meanwhile, in the case of the ultra-high-pressure shower, the investment is around INR 2 crores. We have a very holistic approach. Whatever technologies we are trying to adopt at various locations – be it a new installation, upgradation, or replacement, we are very conscious of the objective that we have to reduce water. That being so, firstly, we try to assess the water footprint of the particular equipment and see if the present level of water consumption could be brought down further. That is our benchmark for putting up any technology. For example, water consumption in hardwood fiberline is around 14-15 m3 per tonne of pulp. In our case, the guarantee by the supplier is 9.5 m3 per tonne of pulp. So, we are undertaking such conscious efforts so as to reduce water at the point of consumption.
Water consumed per tonne of paper produced… Water consumption used to be pretty high in the earlier days. We kept on working towards water conservation and today, it varies between 35-40 m3 per tonne of finished paper, which is quite a low figure given the standards of the paper industry in India right now.
KROFTA INTRODUCES
ANAEROBIC TECHNOLOGY
“The photographs are indicative actual equipment may vary as per requirement”
SALIENT FEATURES OF UASB PROCESS: THE FINAL TREATED WATER CAN BE REUSED TO PAPER PULP MAKING AND MOST IMPORTANT REMOVING SMELL TO FINISHED PAPER PRODUCTS. • No need of special startup requirements. • High treatment efficiency. • Generates non-conventional energy in the form of bio-gas. • Low space requirements as compared with other treatment process. • Very low sludge production. • Low operation cost, low electric power consumption. • No moving parts inside the reactor. • Sludge can be stored for extended periods of time. • Auto operations for higher efficiency.
Krofta Engineering Limited Durga Bhawan, A-68, FIEE Complex, Okhla Industrial Area Phase-II, New Delhi – 110020. 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
MVR System
Measures undertaken to minimise the consumption…
close the loop in every area of the operation itself.
We have studied and done a diagnostic survey of all the available technologies in the market. Then, accordingly, we have tried to replace/upgrade the water conservation technologies. Water conservation cannot be the end of the pipe solution – one has to attack the source of the point of consumption and study each and every area of operation. We have installed mechanical seams in almost all the crucial and critical pumps, in our fiberline due to which, the leakage of water from the seams/tubes is almost zero. Thus, the cooling water given to the seams is being re-circulated which is how we have been able to save a substantial amount of freshwater.
Our plant uses an extensive effluent treatment system. We have a biomethanation plant, and an aerobic system. There is also a pre-treatment after the aerobic system.
The systems are created in such a way that not a single drop of water goes waste in any of the areas. We try to recollect it and then re-circulate it, and then, consciously, wherever we feel that this cannot be further recycled, we send it to the effluent treatment plant. Thus, we try to recycle and reuse it to the maximum possible extent in each and every area. Hence, in this way, we have tried to
Recent developments with regards to water management and treatment… We have recently installed – the Zero Liquid Discharge (ZLD) plant of 2 MLD. Thereby, we are using the membrane technology, followed by Mechanical Vapour Recompression (MVR) technology wherein we evaporate the rejects of the membrane section and recover the water after it condenses. We dissolve the slurry of waste. And there again, we evaporate and condense water from the effluents, and then, finally whatever is left is the salt which is disposed of separately. In this process, we are recovering around 99.5 percent of water. It is still in the trial phase, where we are still establishing the results & the costs of operations, and spending around INR 5 crore on this whole system. We
26 | www.papermart.in / February-March, 2022
hope that this can open a new chapter altogether in the industry in India. We are now trying to scale it up to put up another plant of almost the same capacity so that we can see how it can run more efficiently and economically.
Path-breaking steps taken… At Naini, we are committed to operating and growing our business in a socially responsible way. As an ‘Ethically Firm, Environmentally Strong’ company, we make sure that in everything we do, there is a strong commitment to wider, all-round social progress, as well as to a sustainable development that balances the needs of the present with those of the future. Water conservation has to be achieved collectively as a team. Proper water audits and water conservation plans should be in place and everybody in an organisation has to be very careful about the consumption of freshwater. And that is what we have done in our company. Everybody is very cautious and conscious about how we have to save every single drop of water. And so, that is how you can really bring the water consumption levels down to a great extent.
S•P•E•C•I•A•L F•E•A•T•U•R•E
Trident: Invested INR 20 Crore to Ensure Increased Water Storage Capacity & Reduced Groundwater Abstraction Inputs from Trident Group
Our water treatment process along with wastewater treatment strategies… At Trident, we are committed to making sustainability the centre of all our initiatives. We believe in corporate excellence and social welfare. Our water conservation initiatives, hence, have been aligned with our long-term vision of environmental conservation. These include installing a disc filter recycling system, which recycles the water from the paper machine back into the process. We have our own water treatment and wastewater treatment plants, both of which are equipped with cutting-edge technology. We also keep our water consumption in check and ensure it is within the national best standards for the agro-based pulp and paper industry recycling it at every stage.
Our investment into water treatment infrastructure… Our CSR initiatives are designed in consultation with the management, social experts, community, and other significant stakeholders. We plan our implementation strategy in a way to devise long-term sustainable and scalable solutions. In tune with our goal, we recently invested INR 20 crore to develop our water and wastewater treatment system with advanced technology equipment, resulting in increased water storage capacity and reduced groundwater abstraction. For the treatment of wheat straw washing effluent, we installed a DAF & screw press (a German technology). We have also installed ad-
vanced aerators based on the technology developed in the United States. Moreover, we have charted out a financial plan wherein the company will spend, in every financial year, at least 2 percent of the average net profits earned during the three immediately preceding financial years on sustainable projects in accordance with the CSR policy. The surplus too will be invested back into the CSR activities.
Water consumed per tonne of paper produced… As a result of the water conservation efforts, our water consumption per tonne of paper production is 46.5 kilolitres, which is 7 percent lower than the government norms.
Measures undertaken to minimise the consumption… Trident has been recognised for the measures undertaken for setting up water-efficient machinery, zero liquid discharge systems, kaizen implementation, rainwater harvesting, and so on. We have installed an upgraded sewage treatment facility that provides water for plantations to develop a green belt inside the Trident campus.
28 | www.papermart.in / February-March, 2022
Recent developments with regards to water management and treatment… We have recently upgraded our current setup using advanced technologies. By enhancing the water storage capacity from 4 days to 16 days, we have reduced the ground-water abstraction. We changed conventional clarifier technology to DAF and screw-press for efficient handling of wheat straw washing effluent and replaced conventional technology-based aerators with advanced jet aerators, resulting in lowered operational costs and better quality of treated water.
Path-breaking steps taken… At Trident, we strive to bring a positive change to the existing conditions of the environment. Directing all our endeavours towards achieving sustainable development, we took bold steps to go beyond conventional corporate manufacturing and transform ourselves into an environmentally conscious enterprise. We have undertaken various environmental initiatives including digitalised monitoring of groundwater levels, reduction in GHG emissions, increased waste recovery, and recycling.
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S•P•E•C•I•A•L F•E•A•T•U•R•E
Kuantum Papers: Implemented Water Conservation Measures to Reduce Freshwater Consumption by 2500 m3/day Our water treatment process and wastewater treatment strategies… We, at Kuantum Papers, have a focused approach toward water conservation initiatives. In the last one year, we have implemented water conservation measures to reduce freshwater consumption by 2500 m3/ day or 6 m3/tonne of paper.
Mr. Pavan Khaitan, Managing Director, Kuantum Papers Ltd.
Kuantum has been supplying treated effluent to approximately 2050 acres of land outside its premises for farming. The company has laid down 15 kms of pipeline and five pump sets for the supply of treated water for irrigation in the surrounding villages. As there is no source of surface water nearby, so we are maintaining the entire irrigation network to ensure daily supply of treated effluent to the fields. Thus, we are supporting our community of farmers and have supplemented their livelihood. White water from machines is processed through the disc filter & Micro Plate Settler (MPS) and is then recycled and used back at paper machines. Clarified water is 100 percent recycled back and re-used for dilution of the pulp and consistency regulation and at wire showers at machines.
Effluent Treatment Process We have a full-fledged wastewater treatment process that consists of an equalisation tank followed by clarifiers, an activated sludge plant and bio-clarifier and Upflow Anaerobic Sludge Bed (UASB) reactor. Effluent
30 | www.papermart.in / February-March, 2022
treatment facility at Kuantum Papers is divided into two streams:
Wastewater from agro wet washing lines is handled through the bio-clarifier followed by UASB to generate methane gas which is burnt at power boilers.
Wastewater from the rest of the plant is fed to the full-fledged effluent treatment plant consisting of equalisation tank followed by clarifiers & activated sludge plants.
Our investment into water treatment infrastructure… Kuantum Papers Ltd. has been continuously investing in various freshwater conservation initiatives and wastewater treatment processes. In the last three years, we have invested around INR 30 crores in such measures.
Water consumed per tonne of paper produced… During FY 21-22, water consumption at Kuantum Papers was 48 m3 per ton of paper.
Measures undertaken to minimise the consumption… Technologies used at our plant to reduce freshwater consumption are as below:
Installation of disc filters at paper machines for fiber recovery and reuse of clarified water on the same machines.
Installation of conical save-alls at paper machines for fiber recovery
S•P•E•C•I•A•L F•E•A•T•U•R•E
and clarification of white water and reuse at the same machine.
Use and installation of Micro Plate Settlers (MPS) technology for fiber recovery and white-water clarification and re-use of clarified water at the machines. Installation of new state-of-theart Dissolved Air Floatation (DAF) technology viz. Megacell high-performance filter which is especially used for wet washing filtrate to achieve outlet TSS levels < 300 ppm followed by triple wire sludge dewatering press for sludge handling.
Handling of high chemical oxygen demand (COD) in wastewater through bio-clarifier followed by the UASB reactor which produces methane gas as a by-product which is further used at the power boilers as a fuel.
Recycling back the hot water from the heat exchangers through the cooling tower back into the process.
Use of Volute Press equipment technology for handling of secondary sludge at the effluent treatment plant (ETP).
Installed Triple Wire Belt Press at ETP to handle the underflow sludge from the primary clarifier.
Construction of white water clarifier using High Rate Solid Contact Clarifier (HRSCC) to handle excess white water from paper machines for fiber recovery and reuse of clarified water back to process.
Conscious efforts are being made through various projects to further reduce freshwater consumption by 5 m3/tonne of paper.
Star Paper Mills: Reusing Treated Water in Cooling, Sealing, Cleaning, Gardening and Fire Hydrants Our water treatment process and wastewater treatment strategies… Star Paper Mills strives to maintain harmony with the environment. To facilitate water conservation, we follow 'reduce, reuse, and recycle' philosophy. The treated water is reused in cooling, sealing, cleaning, gardening, fire hydrants, etc. Water is also recycled as part of the process after appropriate treatment. We deploy an activated sludge process for the treatment of wastewater.
Our investment into water treatment infrastructure…
Mr. Madhukar Mishra, Managing Director, Star Paper Mills Ltd.
We have a full-fledged infrastructure for water treatment. Apart from the initial installation cost, the plant has been modernised and upgraded from time to time. In addition, substantial sums are spent as operational expenses every year.
Measures undertaken to minimise the consumption… 32 | www.papermart.in / February-March, 2022
Drawal of freshwater is minimised by using various steps mentioned earlier. It is also noteworthy that most of the wastewater, after treatment, is used by downstream farmers for irrigation so the effective net consumption is very little.
Recent developments with regards to water management and treatment… • Installation of water-efficient showers; • Adoption of medium consistency technology for pulp transfer; • Use of treated water to suppress fugitive emission.
Path-breaking steps taken… We have been proactive in this direction and many of the systems (such as – lime kiln, recovery boiler, fiber recovery system, etc.) that are now common and even mandatory were adopted by us long ago.
S•P•E•C•I•A•L F•E•A•T•U•R•E
Emami Paper Mills: Adopting the Principle of ‘Reduce, Reuse, Recycle and Recover’ Our water treatment process and wastewater treatment strategies… Emami Paper Mills has already implemented the latest technologies in fiber recovery, a closed water loop for water-saving, and an online monitoring system for a green and clean environment. Today, it has also achieved the status of zero solid waste by adopting the principle of ‘Reduce, Reuse, Recycle and Recover’. Wastewater generation is minimised by effectively recycling, and utilising it for paddy cultivation, plantation, gardening and plant use.
Mr. Vivek Chawla, Whole Time Director and CEO, Emami Paper Mills Ltd.
The first step towards efficiently managing and conserving water resources is monitoring and mapping water consumption under various processes. This involves conducting a regular water audit that identifies and quantifies water uses and losses from a water system. Our effluent treatment plant is designed to handle the entire wastewater generated in the process. Our ETP is provided with primary clarifiers followed by UASBR (Up-flow Anaerobic Sludge Blanket Reactor), diffused aeration systems and secondary clarifiers. Continuous online monitoring systems are installed in the final treated wastewater discharge point and the parameters such as pH, TSS, COD, and BOD are continuously transmitted to SPCB/CPCB.
Our investment into water treatment infrastructure… The investment in the company’s wastewater treatment infrastructure is approximately INR 50 crore.
34 | www.papermart.in / February-March, 2022
Water consumed per tonne of paper produced… Present water consumption is around 13KL per tonne of paper produced.
Measures undertaken to minimise the consumption… In Board Plant: • Planned to install high-pressure single-point scanning showers. • Screens sealing water is returned back to the sealing water tank for reuse. • All machines are equipped with disc save-all for fiber recovery & for better separation of the backwater for reuse in the system. In Paper Machines: • Reduction of nozzle diameter of HP & LP showers in all machines. • Installed disc filter for better fiber recovery and using super clear water for LP showers, edge sealing (wire part), etc. • Reuse of filter backwash in PM4 process cooling tower makeup. • A dissolved air floatation system is installed to recover and reuse the clear water in the manufacturing process. • Recycling of sealing water in all machines. In Power Plant: • Evaporation & drift losses are optimised by installing counter flow cooling towers with drift eliminators and maintaining the system parameters. • Blowdown water from the cooling towers and the boilers are being recycled in the manufacturing process.
S•P•E•C•I•A•L F•E•A•T•U•R•E in the process. With the installation of clariflocculator in the board machine, there is a saving in freshwater consumption and it has reduced the hydraulic load on ETP.
Path-breaking steps taken…
• RO Plant rejects are being recycled in the process and ash conditioning.
conditioning and water sprinkling purpose over the entire plant, etc.
• Usage of ETP treated water for screw press shower after adequate treatment
Recent developments with regards to water management and treatment…
• ETP final treated water is used in various non-process areas like dust suppression in a coal yard, gardening/plantation area, ash
We have installed a clariflocculator in the board machine area for the treatment of process water from the machine and to use the clarified water
The total primary sludge from ETP is taken to the sludge tower of the sludge dewatering plant. This sludge is treated with organic coagulant & flocculent, and taken to pre-thickener to improve the consistency from 3.5 percent to about 15 percent. Sludge is dewatered through a screw press to the dryness level of 50-55 percent. This dried primary sludge is used as co-fuel along with coal in the power boiler (Coal saving – 10500 MT/annum). There has been utilisation of 100 percent fly ash generated in local brick manufacturing units (approximately 300 units).
Shreyans Industries: Encouraging Proper Wastewater Management Inputs by Mr. Rajneesh Oswal, Chairman & Managing Director, Shreyans Industries Ltd.
Our water treatment process and wastewater treatment strategies… We have a water treatment plant based on anaerobic and aerobic treatment. The raw material wash effluent is treated anaerobically before being mixed with the other mill effluent. The aerobic system consists of double aeration equipped with a pure oxygen injection system in aeration tanks. Moreover, Poly Aluminium Chloride (PAC) is being used for de-colouring the wastewater.
Our investment into water treatment infrastructure… We have installed a pure oxygen injection system at the effluent treatment plant. Fixed investment in the effluent treatment plant is around INR 25 crore and the monthly expenses are around INR 50-55 lakh.
Water consumed per tonne of paper produced… The consumption of water is around 50-52 KL to produce 1 tonne of paper.
Measures undertaken to minimise the consumption… To minimise the consumption and reduce wastewater discharges, we re-
36 | www.papermart.in / February-March, 2022
circulate machine backwater to the pulp bleaching section. Also, combine condensate from the evaporator section is being reused in the pulp mill. Pure steam condensate from the paper machine, dryers, and recovery plant evaporators, is being circulated to the boiler house and final treated wastewater is being reused for washing of raw materials.
S•P•E•C•I•A•L F•E•A•T•U•R•E
BILT Graphic Paper Products: Installing Best Available Technology for Recycling of Water within Production Process Our water treatment process and wastewater treatment strategies… Our quest for sustainable development has guided us to implement various water conservation projects with the principle of ‘Take less from nature to protect our mother earth for future generations.’ Accordingly, in every stage of decision-making process, environmental protection is given priority. To achieve this goal, a separate Environment & Pollution Control Department is operational since the establishment of the mill.
Mr. Nagendra Krishna Bhat, Vice President & Unit Head, BILT Graphic Paper Products Ltd., Unit – Bhigwan
In addition, we have focused on installing the best available technology for recycling of water within the production process. Some of the important equipment which are aiding in water conservation are as follows. • Advanced fiber recovery systems viz disc filter are used to recycle the process white water for showers, chemicals preparation, consistency controls etc.
• TURBAIR vacuum blowers installed instead of traditionally used liquid ring vacuum pumps (which require huge amount of sealing water). • Indirect condenser for deculator system - We have adopted the latest design of tube heat exchanger as indirect condenser in the deculator vacuum system. • Avoided direct water injection enabling its outlet cooling water to be reused in the shower water system, thereby saving fresh water to the tune of approximately 400 m3/day. • Partial quantity of ETP treated water is processed through RO system (60 m3/hr) and reused in place of fresh water during water scarcity situation. Effluent water treatment process at ETP We have a 5-Stage state-of-the-art Effluent Treatment Plant – primary clarifier, aeration tank, secondary clarifier, tertiary clarifier, pressure sand filter, aeration cascade.
Effluent Treatment Plant & Treated Water Utilisation [Capacity : 22500 m3/Day ]
I Stage Flow Meter
Coagulant and Flocculant
Screening
Primary Primary Clarification Clarification Under flow Sludge
Effluent from plant
II Stage
Nutrients (Domestic Sewage)
Primary Primary sludge Thickener Thickener De-watering in Belt Press
IV Stage
V Stage
Filter Filter feed feed sump sump
Biological Biological Reactor Reactor
Secondary Clarification
Bio-sludge Recycle (MLSS) Clarified Water
Sludge Secondary Sludge Thickner Thickner
OR
Sludge sold to board manufacturers/burnt in boiler
38 | www.papermart.in / February-March, 2022
III Stage
De-watering De-watering in Centrifuge Centrifuge
Tertiary Tertiary Clarification Clarification
Duel Media Dual Media Filter Filter
Cascade Cascade Aeration Aeration
Under flow Slurry
Plantation & Gardening Back Wash Sump
Recycle & Reuse in Process Farmers for irrigation
Online Monitoring station
Treated Treated Water Water Storage tank St. Tank
Orchid Laminates (OLPL) is engaged in the manufacturing of Coated Paperboard, Kraft Paper and High Pressure Decorative Laminate Sheets (HPL Sheets).
Coated Paper Board / Duplex Paper board (High Gloss Coated/Trim & Dust Free paper) PRODUCTION CAPACITY: 80000 TPA
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ORCHID LAMINATES PVT LTD (UNIT-1)
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Plot No.298, Road No.1 & 2, 2nd Phase Harohalli Industrial area, Ramanagara District, Harohalli, Bangalore-562112.
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080-25594207 info@olpl.in www.olpl.in
S•P•E•C•I•A•L F•E•A•T•U•R•E
Primary Clarifier
Aeration Pond
Secondary Clarifier # 1
Secondary Clarifier # 2
Tertiary Clarifier
Aeration Cascade
Our investment into water treatment infrastructure… More than INR 27 crore has been progressively invested in the effluent water treatment so that effluent water quality is maintained for reuse and for irrigation.
Water consumed per tonne of paper produced… Through our continuous efforts in reducing fresh water consumption, we have been able to achieve a specific water consumption of 12 m3/MT of paper.
Path-breaking steps taken… It has been our endeavour to maximise the use of treated effluent back in the process, in tree plantation, and for agriculture. Accordingly, most of our treated effluent is currently being utilised for the following applications:
Green belt development and gardening (company and colony premises) o Treated effluent utilisation for Green belt development Total
lakhs
Number of plants: 1.96
Measures undertaken to minimise the consumption…
Total
area covered by plantation: 106 hectares
Total
capital expenditure: INR 108 lakhs
Paper and power plant process/coal plant & ash plant
Farming by nearby farmers (with bilateral agreement)
Awards Related to Water Conservation & Environment.
Water Efficiency Award – 2014 – 2015 from PPI International
Environmental Award – 2013 – 14 from PPI International
Paryavaran Gaurav Puraskar – 2012 – 2013 from RO , MPCB Pune
S.No. Description 1
Installation of RO plant to partially reuse ETP treated water in the production process.
Water Efficiency Award – 2012 – 2013 from PPI International
2
Recycling of super clarified filtrate from Disc Filter in paper machine showers.
3
Deculator sealing water circulated back in to the system as replacement of fresh water in fresh water showers.
Excellent Water Efficient Unit Award – 2012 – 2013 from CII
4
Chemical dilution ratios optimised to reduce fresh water consumption.
5
Vacuum pump sealing water is used in shower water.
Earth Care Award for GHG Mitigation Large Enterprises – 2011 – 2012 by Govt. of India
The treated effluent is used as the substitute for fresh water for floor cleaning, chemical tank cleaning, fly ash brick making, fly ash and coal dust suppression etc.
6
Excellent Water Management Award – 2011 – 2012 from CII
Cooling tower make up by reusing the Ultra filtration backwash water and boiler blowdown water.
7
Good Green Governance (G3) Award by – 2011 – 2012 by Srishti Publication Ltd., New Delhi.
40 | www.papermart.in / February-March, 2022
S•P•E•C•I•A•L F•E•A•T•U•R•E
N R Agarwal Industries: Recovering 2300 m3 Water per day through Tertiary Treatment in the form of RO Our water treatment process and wastewater treatment strategies… Growing water scarcity and heightened awareness associated with water conservation are prompting more industrial manufacturers to explore water recycling within facilities – a strategy that also reduces wastewater effluent volumes. Water recycling is an attractive proposition for industries such as pulp & paper that withdraw large volumes of water or have highly polluted waste streams and are subject to increased charges for disposal.
Mr. R N Agarwal, Chairman & Managing Director, N R Agarwal Industries Ltd.
Many of the progressive initiatives in the pulp & paper industry regarding water treatment and reuse have been a direct result of the growing importance of corporate and environmental responsibility. The paper industry has made great improvements in treating process water streams and recovering residual pulp fibers, calcium carbonate, and water volume.
42 | www.papermart.in / February-March, 2022
We, at N R Agarwal Industries, are also working hard in order to reduce water consumption in our all units, and adopting the latest technologies for the treatment of wastewater to achieve the goal and we are successful in reducing a substantial amount of water consumption. As far as the treatment system is concerned, for the writing & printing unit, we have a buffer tank cum equalisation tank followed by a screening system/flash mixer and flocculator before treating the rich wastewater in the primary clarifier wherein suspended solids are removed and the clear water is treated for the secondary stage, that is, a biological treatment followed by secondary clarifier. We also have tertiary treatment in the form of RO and recover almost 2300 m3 of water per day, which is a direct saving of freshwater. Running RO is a complicated process, as we initially installed a 1000 m3 per day capacity RO and faced a lot of problems including very high treatment costs. Later on,
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S•P•E•C•I•A•L F•E•A•T•U•R•E we rectified all the issues with huge investment and also installed an additional RO line of 1300 m3 per day capacity. Today, we can proudly say that our both RO systems are running continuously and are giving the desired output of 2300 m3 per day.
further reduce water consumption. In the last three years – 2019 to 2021, we have invested more than INR 37 crore in increasing the capacity of secondary treatment and installing a new tertiary treatment system in the form of RO.
For board units, we have a fullfledged treatment system and use the maximum possible treated water in the system and thereby controlling freshwater consumption.
Water consumed per tonne of paper produced…
Our investment into water treatment infrastructure…
Measures undertaken to minimise the consumption…
We are continuously investing in the treatment of wastewater in order to
We are able to reuse the treated wastewater back into the system, re-
Our water consumption per tonne of paperboard is hardly 3.5 m3.
sulting in the reduction of wastewater discharge quantity.
Path-breaking steps taken… The environmental problems of the pulp & paper industry are not limited by the high water consumption. Wastewater generation, solid wastes including sludge generated from wastewater treatment plants, and air emissions are other problems and effective disposal and treatment approaches are essential. We have adopted the technologies wherein solid waste is being used as a source of energy thereby reducing the use of steam coal and saving the environment.
Yash Pakka: Our Goal is to Reduce Water Consumption to 25 m3/MT Our water treatment process and wastewater treatment strategies… Tremendous efforts and actions have been made and implemented at Yash Pakka for water conservation. The withdrawal has been reduced by almost 30 percent. This has a combined effect of reducing the treated water in the stream and overall reduction at the source as well. It is one of the high-level mission targets for the organisation, year on year basis.
Our investment into water treatment infrastructure… The investment of the company towards the reduction and reuse of water is around INR 800 lakhs. Mr. Jagdeep Hira, Business Head, Yash Pakka Ltd.
Water consumed per tonne of paper produced… The water consumption for the current year is 37 m3/MT and the target is to further go down to 25 m3/MT by the end of this year.
Measures undertaken to minimise the consumption… 44 | www.papermart.in / February-March, 2022
Revamping of the entire effluent treatment plant is being carried out, with additional capacities on aeration. We have also undertaken installation of plate settlers deployed at individual sources for its maximum utilisation. Tertiary with post filtrations have been initiated. Further, we are also in the process of installation of anaerobic digesters for the pre-conditioning of wastewater.
Path-breaking steps taken… Our organisation’s vision is to be a leading global producer of compostable products. Having said that, we adopt environmentally friendly practices in the process of manufacturing, minimising, and targeting high levels to reduce and reuse water. We have robust rainwater harvesting systems across the plant. We are continuously adopting new technology in an endeavour to control gaseous emission norms. As a mission, we have also been aggressively working on pond restorations in the nearby localities.
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S•P•E•C•I•A•L F•E•A•T•U•R•E
Silverton: Installed Fiber Recovery Cells to Clarify Wastewater locations where usage of freshwater is mandatory. We have a proper effluent treatment plant which is having primary clarification system, aeration system, and secondary clarification system with a tertiary system for ensuring wastewater quality standards as per the pollution control department.
Our investment into water treatment infrastructure…
Mr. Akshay Jain, Director, Silverton Pulp and Paper Pvt. Ltd.
Our water treatment process and wastewater treatment strategies… We have installed a rainwater harvesting system for conserving rainwater. Additionally, we draw minimum groundwater and maximise recirculation of used water except in critical
A substantial amount of investment is made in the water treatment system over a period of time for maintaining proper effluent standards. We have installed an ‘each and every minute’ system for proper treatment.
Water consumed per tonne of paper produced… We manufacture two grades – one is kraft paper, which requires around 2-3 KL of water per tonne, and the other is writing & printing which requires around 10-15 KL of water per tonne.
Recent developments with regards to water management and treatment… We have installed fiber recovery cells to clarify wastewater and reuse it so that water consumption can be minimised. One more important piece of equipment to reduce water consumption is a robo shower which we have installed in our paper machine for reducing the substantial amount of fresh water in the system.
Path-breaking steps taken… We are continuously working towards making our mill more environment-friendly. We are going for a new MSW boiler to generate power and steam through which we can serve our community by cleaning municipal waste. Many other technologies for air quality improvement, water quality improvement, water conservation, plantation, etc. are adopted by our company on a regular basis.
Sukraft: Ensuring ZLD at All Units Our water treatment process and wastewater treatment strategies… All of our six manufacturing units are zero discharge and we have been practicing this since 2001. We have always had such a sense of responsibility.
Our investment into water treatment infrastructure… We have installed ICX reactors in 2 of our units. In the times to come, we will install similar reactors in other units as well. Mr. Shankar Patel, Managing Director, Sukraft Group
46 | www.papermart.in / February-March, 2022
Measures undertaken to minimise the consumption… Water management is going to play a very important role in the future. It is a social responsibility as well as a regulation from the government. The days are over when mills used to discharge their untreated water to rivers and other natural sources. I want to add that the paper mills of the future will require more land area than it was needed in past. Every new unit will have to keep a substantial area of land for its ETP and other water treatment setups.
S•P•E•C•I•A•L F•E•A•T•U•R•E
48 | www.papermart.in / February-March, 2022
GETTING GREENER
Forestry Practices of Paper Mills
T
he paper industry is blamed for deforestation and the felling of trees. We often receive e-mails with the tagline “Please consider the environment before printing this email” or “Save Paper — Think Before you Print”. However, the scenario is not what it looks like. It’s true that paper requires cellulose pulp and fibers from trees but that is just the tip of the iceberg. While wood accounts for 21-22 percent of raw material usage, nonwood sources including wastepaper and agro residue-based account for 70 percent and 8 percent, respectively (according to the CPPRI report of 2019-20).
Sustainable Story of Paper Mills The paper industry in India is not based on the forest but on agro/farm forestry. Just like any other crop, the trees are grown by farmers on their lands and their harvest is sold to paper mills. A large part of this wood is grown in the land which is usually considered unfit for other use and the tree saplings are drought-resistant and can be grown in different climatic conditions. This not only turns unproductive land into pulpwood plantations but also generates employment.
Talking about ITC’s Afforestation Programme, Mr. Sanjay Singh, Group Head - Paper & Packaging at ITC Ltd. says, “The programme assists farmers to turn their unproductive land assets into profitable pulpwood plantations, using clonal saplings specially developed by ITC R&D to grow in harsh conditions. Every year, we are planting 15 to 20 thousand hectares of plantation on farmers’ land which is way more than our requirements.” Besides this, ITC has set up a state-of-the-art clonal production facility spread over 30 acres of land, near its Bhadrachalam unit. The clonal production centre was commissioned in the year 2013 with a production capacity of 15 million saplings and is the largest facility for pulpwood tree species clonal nursery in India. The large-scale paper mills in India aim to plant more trees than they consume. “We are consuming around 3 lakh MT of wood and plywood waste per annum whereas we are now supplying clones and seed sapling for plantation in around 25000-hectare area generating 35 lakh MT of wood per year. Our social forestry activities for the generation of wood are more than 10 times and much surpassing our annual consumption,” says Mr. Madhukar Mishra, Managing Director, Star Paper Mills Ltd. www.papermart.in / February-March, 2022 | 49
S•P•E•C•I•A•L F•E•A•T•U•R•E Promoting Agro/Farm Forestry Meanwhile, the budget proposal for a policy initiative to promote agroforestry in the country is expected to provide an impetus to the agro/farm forestry drive of the paper mills. “We greatly welcome the statement of the Finance Minister that policies and required legislative changes to promote agroforestry and private forestry will be brought in. Despite the tremendous efforts of the paper industry in promoting plantations in the country, the availability of wood domestically is inadequate compared to the demand of India’s paper industry,” said Mr. AS Mehta, President, Indian Paper Manufacturers Association (IPMA), and President & Executive Director, JK Paper Ltd. “Pioneering work has been carried out by the paper industry over the last three decades in promoting agro/farm forestry in the country. In
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India, an estimated 5 lakh farmers are engaged in growing plantations and around 12 lakh hectares on a cumulative basis across the country have been brought under plantations due to intensive efforts mounted by paper mills over the last several years,” he added. The paper industry in India is woodpositive – it grows more trees than it uses. Thus, it won’t be wrong to say that for every tree that is cut, several are planted in its place. Interestingly, not just wood-based paper mills, bagasse, and recycled-paperbased mills are also engaged into plantation of trees as they see this as a necessary investment in the future as a safeguard against raw material and fuel availability. As the world celebrates International Forest Day on 21 March, Paper Mart highlights the significant contribution made by the paper mills in increasing the green cover.
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ITC’s Afforestation Programme turns Unproductive Land into Profitable Pulpwood Plantations
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he afforestation programme of ITC Ltd. brings multiple benefits to multiple stakeholders. Plantation incomes are significantly higher, especially beneficial for poor farmers, helping them to step away from penury and deprivation. For Indian paper producers, the plantations create a raw material source that is local, renewable, and responsible. They also contribute to expanding the country’s green cover thereby enabling large-scale sequestration of carbon dioxide, enriching depleted soils, and replenishing groundwater. In an interview with Paper Mart, Mr. Sanjay Singh, Group Head Paper & Packaging at ITC Ltd. talks in detail about the company’s social and farm forestry programmes.
Mr. Sanjay Singh, Group Head - Paper & Packaging, ITC Ltd.
Every year, we are planting 15 to 20 thousand hectares of plantation on farmers’ land which is way more than our requirements.
52 | www.papermart.in / February-March, 2022
Paper Mart: Please tell us about your pro-afforestation schemes. How much area is covered under plantations by you and what percentage of raw materials do you procure from social and farm forestry? Sanjay Singh: ITC’s Afforestation Programme assists farmers to turn their unproductive land assets into profitable pulpwood plantations, using clonal saplings specially developed by ITC R&D to grow in harsh conditions. We get a hundred percent of our raw material from plantations done either by us or by the forest department. Not a tonne is taken from natural forests. Every year, we are
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The recent announcement by the Government of India in this financial year’s budget should go a long way in promoting forestry and growing trees for various sectors in the country. planting 15 to 20 thousand hectares of plantation on farmers’ land which is way more than our requirements. The company’s pioneering afforestation initiative is currently spread across 17 districts in 8 states covering over 3.94 lakh acres in 5,694 villages, impacting over 1.28 lakh households. Together with the company’s farm forestry programme, this initiative has greened over 8.76 lakh acres to date and generated about 160-million person-days of employment for rural households, including poor tribal and marginal farmers. Integral to the social forestry programme is the agroforestry initiative, which cumulatively extends to over 1.23 lakh acres.
PM: Tell us about the hardwood and softwood trees that are grown by the mill. Do you think that sourcing wood from farm forestry is a win-win situation for both mills as well as farmers who want a steady source of income? SS: We are growing only hardwood trees like Eucalyptus, Casuarina, and Subabul. Our plantation programme is a win-win situation for us as well as farmers. For small farmers who need a regular income, we follow the social forestry model wherein the trees are widespread, and in-between they can grow crops like maize and chickpea. From these yearly crops, they are able to make ends meet and after four years they get a lump sum from harvesting trees. We also encourage farmers with sufficient finances, who are not dependent on yearly crops, to grow pulpwood plantations on low
We also encourage farmers with sufficient finances, who are not dependent on yearly crops, to grow pulpwood plantations on low productivity/degraded landholdings for higher earnings and environmental benefits.
productivity/degraded landholdings for higher earnings and environmental benefits. Thus, we cater to all types of farmers.
PM: Do you think that India’s agroforestry policy is a step in the right direction? How do you think the recent announcement of policies and legislative changes to promote agroforestry and private forestry in Budget 2022 will help? SS: The recent announcement by the Government of India in this financial year’s budget should go a long way in promoting forestry and growing trees for various sectors in the country. For the pulp and paper industry, it is a step in the right direction. We would like to work closely with the government on these projects. It helps to improve employment in rural areas which will reduce migration from villages to towns.
PM: Have you been able to improve the productivity of degraded lands, control soil erosion, and push moisture
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conservation through your social farm forestry program? SS: The paper mills that make their own pulp have survived only because of the agroforestry model. In this arrangement, we work with small and marginal farmers and on wastelands that were lying idle. This has helped in substantially increasing the green cover, improving the quality of soil, controlling soil erosion, increasing water level, and improving farmers’ income.
PM: What are your company’s future targets in the area of farm forestry? SS: ITC’s Afforestation Programme aims at greening degraded lands, creating sustainable livelihoods, and augmenting India’s green capital through multi-stakeholder partnerships. Moreover, growing more trees will even lay the groundwork for setting up new pulp mills, which, in turn, will enable the country to save foreign exchange.
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TNPL: Uplifting Lives of Farmers and Paving the Way to Empower Society as a Whole
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Thiru. S. Krishnan (IAS), Chairman and Managing Director, Tamil Nadu Newsprint & Papers Ltd.
The main objective of the TNPL plantation scheme is to rehabilitate and restore the degraded and marginal farmlands through sustainable plantation management practices for increased production of pulpwood.
stablished in the 1980s, Tamil Nadu Newsprint & Papers Ltd. is an acknowledged leader in the technology of manufacturing paper from sugarcane fiber and wood pulp. The company today enjoys the status of being one of the most environmentally benign mills in the country. TNPL’s plantation programme envisaged developing pulpwood cultivation broadly under two schemes, i.e. captive plantation and farm plantation. Such plantation schemes have been instrumental for local and marginalised farmers to gain livelihood and financial independence. In an interview with Paper Mart, Thiru. S. Krishnan (IAS), Chairman and Managing Director, Tamil Nadu Newsprint & Papers Ltd., talks about the company’s pro-afforestation schemes, manufacturing capabilities, and world-class technology.
Paper Mart: Please tell us about your pro-afforestation schemes. How much area is covered under plantations by you and what percentage of raw materials do you procure from social farm forestry? S. Krishnan: TNPL put forth continuous effort to become self-reliant and also self-sustainable in meeting its raw material demand through implementing various plantation schemes viz., farm forestry and captive plantation. Under the farm forestry scheme, TNPL motivates individual small and marginal farmers and institutions to raise fast-growing pulpwood plantations by supplying high-quality pulpwood clonal plants at subsidised rates and providing technical assistance to raise pulpwood plantations.
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Under the captive plantation scheme, TNPL enters into an MoU with landowners for the establishment of plantations on their land either on a gross revenue sharing basis. The minimum landholding should be 50 acres and above. As per the MoU, TNPL makes all the expenditures right from land development, planting, and maintenance to harvesting, and the gross revenue will be shared between the landowner and TNPL. ‘Progress is impossible without change’, henceforth, the plantation department has also progressed further by introducing one more additional scheme namely demonstration plots. These new schemes serve as a platform for showcasing the new improved TNPL clones to increase the unit area productivity and achieve maximum benefit from a minimum area with an aim to benefit both the company and farmers. These schemes have been implemented over 2,11,280 acres by supplying more than 270 million quality clonal plants all over Tamil Nadu in the past 17 years.
PM: Tell us about the hardwood and softwood trees that are grown by the mill. Do you think that sourcing wood from farm forestry is a win-win situation for both mills as well as farmers who want a steady source of income? SK: TNPL is raising pulpwood plantations of various species like Casuarina, Eucalyptus, Melia, Gmelina, Subabul, and Sissoo, which are hardwood species suitable for Tamil Nadu climatic conditions. We do not use any softwood in our pulp production. TNPL is
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procuring the pulpwood directly from farmers without any intermediary and making payments in their bank accounts. This ensures transparency in payment and better prices paid to farmers. The systematic approach by supplying quality clonal plants, timely support in maintenance & harvest of pulpwood, and the fair price paid to farmers ensure the sustained availability of pulpwood to the company and guaranteed market support with better remuneration to the farmers. TNPL is continuously procuring pulpwood directly from farmers at assured prices. Further, TNPL is also improving the productivity of plantations by introducing high-yielding new clones, which will increase the productivity per unit area, ultimately increasing the farmer’s income. TNPL also gets maximum pulpwood from the limited area near the mill site. Therefore, this is really a win-win situation for both TNPL and farmers.
PM: Do you think that India’s agroforestry policy is a step in the right direction? How do you think the recent announcement of policies and legislative changes to promote agroforestry and private forestry in Budget 2022 will help? SK: India’s agroforestry policy is in the right direction to increase the area under farm plantations on farmer’s land. Even though paper industries are doing a commendable job in promoting agroforestry, any promotional activities with suitable legislation will provide huge impact and success. In line with this, the recent announcement of
policies and legislative changes to be brought in to promote agroforestry and private forestry in Union Budget 2022, will gain confidence among the farming community to raise agroforestry plantations. In addition to the legislative changes, the Government of India will also provide financial support to develop agroforestry plantations on the farmland. With this kind of support from the government, the area under agroforestry plantations will increase throughout the country. Besides providing sustainable income to farmers, agroforestry plantations also provide ecological services like carbon sink which will be resulted in a ‘Carbon Neutral Economy’ in our country.
PM: Have you been able to improve the productivity of degraded lands, control soil erosion, and push moisture conservation through your social farm forestry program (along with a case study, if possible)? SK: Although pulpwood plantations are mainly intended to produce wood to ensure the sustained availability of raw material, these plantations also enhance the environmental benefits. The main objective of the TNPL plantation scheme is to rehabilitate and restore the degraded and marginal farmlands through sustainable plantation management practices for increased production of pulpwood. The silviculture activities like ploughing the barren degraded land across the slope and forming bunds along the contour, which not only loosen the soil but also control the runoff & soil erosion, collect maximum rainwater and allow water to
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percolate into the subsoil. Further, the leaf litterfall on the ground will be incorporated into the soil by carrying out inter ploughing once in six months till its maturity, adding to the organic content of the soil. This will improve the soil moisture retention capacity of degraded lands. TNPL also creates awareness among the farming community to adopt these soil and moisture conservation technologies through various training programmes.
Case Study TNPL executed an agreement with the HR&CE Department Government of Tamil Nadu to utilise the barren land belonging to various temples in Tamil Nadu by raising Captive plantation to an extent of 2508.55 acres in Tirunelveli, Tuticorin, and Virudhunagar Districts. TNPL has developed the degraded barren lands by executing various land development works including soil moisture conservation practices like contour bunds, creating rainwater-harvesting ponds, etc., and raised pulpwood plantation. The benefit derived from the above projects are: • Utilisation of vacant land belonging to temples for productive use; • Increased the green cover to create a better environment; • Improved the soil fertility status; • Conserved the soil moisture; • Provided substantial income to temples from barren lands; and • Generate raw material for the industry from barren non-forest land. This is one of the classic examples of industry and government depart-
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ment partnerships to improve the productivity of degraded lands, control soil erosion, and push moisture conservation through a captive plantation scheme.
PM: What are your company’s future targets in the area of farm forestry? SK: In the view of mill expansion in TNPL Unit II, the annual pulpwood requirement increased from 5 lakhs
MT to 10 lakhs MT. Varying climatic conditions, soil types, fluctuating water availability, and diminishing land availability, pose a challenge. Apart from Eucalyptus and Casuarina species, screening of alternative pulpwood species and development of high yielding pulpwood clones through various tree improvement programme are undertaken. To meet this huge requirement, TNPL has fixed the plantation target of 25,000 acres/annum to be developed
under various plantation schemes. To achieve this plantation target, annually about 50 million clonal plants are to be produced and supplied for which TNPL has established the required infrastructure. TNPL does not want to stop here. It continues this journey of success that is committed to the environment, uplifts the lives of farmers, and paves the way to empower society as a whole.
Trident Group: Embracing Sustainability as Core Business Vertical and Paramount Responsibility
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rident Group is one of the nationally preferred suppliers of high-quality branded copier paper and paper for multi-colour highspeed printing & publishing. The company delivers ‘The Good Paper’ made from wheat straw and provides an additional source of income to all its associated farmers. Working towards becoming good stewards of the earth, the group has planted over 6 lakh trees within its premises. In an interview given to Paper Mart, Team Trident gives valuable insights into the determined efforts it has been putting for a greener environment.
Paper Mart: Please tell us about your pro-afforestation schemes. How much area is covered under plantations by you and what percentage of raw materials do you procure from social farm forestry? Team Trident: Trident Group embraces sustainability as a core business vertical and its paramount
Our endeavours are aimed at paving the way for a safe and healthy environment by developing eco-friendly products such as paper from agro-residue, managing unused resources, and rainwater harvesting. We source all our wood raw materials from social and agroforestry sources.
responsibility. Our endeavours are aimed at paving the way for a safe and healthy environment by developing eco-friendly products such as paper from agri-residue, managing unused resources, producing organic yarn, and rainwater harvesting. We source all our wood raw materials from social and agroforestry sources. As far as the mill’s location is concerned, the Malwa area of Punjab is known for its seasonal crops (Kharif and Rabi), which in-
60 | www.papermart.in / February-March, 2022
clude wheat and paddy. Due to high soil fertility and production, the concept of agroforestry is lacking in neighbouring areas, resulting in farmers earning a fair living from agricultural crops. Mills, on the other hand, are planting trees on millowned land on a regular basis.
PM: Tell us about the hardwood and softwood trees that are grown by the mill. Do you think that sourcing wood from farm
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forestry is a win-win situation for both mills as well as farmers who want a steady source of income? TT: We are cultivating Eucalyptus SPP, a prominent hardwood used in pulp and paper production. As this is a tropical/semi-arid zone, softwoods cannot be cultivated. As far as sourcing wood from farm forestry is concerned, agro/farm forestry has been a significant source of revenue for farmers in recent years. They benefit from it in two ways, i.e., seasonal income from agricultural produce and fixed income from tree produce after every fixed 4 to 5 years of rotation, resulting in the most efficient use of land in locations where soil fertility is moderate.
PM: Do you think that India’s agroforestry policy is a step in the right direction? How do you think the recent announcement of policies and legislative changes to promote agroforestry and private forestry in Budget 2022 will help? TT: The National Agroforestry Policy of India is a comprehensive policy framework aimed at improving agricultural livelihoods by maximising agricultural productivity to mitigate climate change. Budget 2022 has proposed policy and legislative changes to promote agroforestry and private forestry. It also specifies financial support to farmers belonging to Scheduled Castes and Scheduled Tribes who want to take up agroforestry. Tribal communities hold vast knowledge of traditional agroforestry systems and practices that promote productivity, adaptability, and sustainability, and can contribute immensely to the rural economy, employment, and poverty alleviation at a local level. The budget is also focused on transitioning to a carbon-neutral economy as plants are being set up to achieve carbon-dioxide savings of 38 million metric tonnes annually. In addition, reduced alternate minimum tax rate and surcharge for cooperatives have been proposed by
There are plans in the pipeline to build a separate team that will be responsible for distributing clones to local farmers as well as developing greenhouse projects on the plant grounds to work on cultivating clones and possible hybrid fast-growing pulpwood species.
the Finance Minister to bring down the minimum tax for the former from 18.5 percent to 15 percent. Also, the surcharge on cooperative societies generating a total income ranging from 1 crore to up to 10 crores will be reduced from 12 percent to 7 percent to help enhance the earnings of the societies and their members who are primarily from rural and farming communities. Under Rashtriya Krishi Vikas Yojana, the Budget saw an allocation of INR 10,433 crore under this scheme for 2022-23—nearly triple the budgeted estimate of INR 3,712.44 crores in the current fiscal. Further, the increase is more than five times the revised estimate. The advantage of the scheme is that it gives the states more freedom to develop and implement their own agricultural plans, and increased funding will facilitate the states to exercise the funds in a way they see fit, based on regional and local priorities Budget 2022 has also restored the Krishi Unnati Yojana (KUY). It comprises a cluster of 10 schemes different from what was first announced and includes some of the older Green Revolution schemes. It currently has a budgetary allocation of INR 7,183 crore, 26 percent of which is for the development of the horticulture sector and 21 percent to encourage the domestic production and processing of palm, edible oil and oilseeds. All the above shall directly or indirectly boost green cover and agroforestry /horticultural reforms will flourish.
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PM: Have you been able to improve the productivity of degraded lands, control soil erosion, and push moisture conservation through your social farm forestry program? TT: Considering the mill’s position, the soil is extremely fertile, with little traces of degraded or barren areas. Farmers in other states of India are already practising seasonal crops with the maximum yield per acre productivity for paddy and wheat. As a result, the notion of agricultural forestry is not as prevalent in Punjab as it is in Uttar Pradesh and Haryana.
PM: What are your company’s future targets in the area of farm forestry? TT: We are focused on strengthening our relationship with a greener planet and we are actively working towards fulfilling our commitment to achieving carbon neutrality, embedding energy-efficient equipment in plants, and using biogas generated from food waste. We plan to do these more in near future. Hence, there are plans in the pipeline to build a separate team that will be responsible for distributing clones to local farmers as well as developing greenhouse projects on the plant grounds to work on cultivating clones and possible hybrid fast-growing pulpwood species.
KPL INTERNATIONAL LIMITED KPL International Ltd. is a professionally managed international trading company. Major activity of the company is marketing quality products in the Indian subcontinent, primarily chemicals, paper, polymers and allied products, sourced from more than 50 globally acclaimed manufacturers. With a customer base of over 5000 spread across the Indian Subcontinent and warehousing facility in all major regions, we take pride in working as an “extended arm” of our suppliers & principals.
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Kuantum Papers: Planning to Expand Clonal Saplings Production to 1 Crore p.a. in Next 5 Years Since 2008, we have constantly worked on upgrading our own Clonal Propagation Centre (CPC), which now has a production capacity of around 10 lakh saplings per annum.
K Mr. Pavan Khaitan, Managing Director, Kuantum Papers Ltd.
uantum Papers Ltd. is an integrated agro and wood pulp-based paper manufacturer. Since 1979, the paper mill has been producing writing and printing, copier, and specialty papers from various kinds of agricultural residues, straws, bagasse, and wood. Located in Punjab, Kuantum Papers is an environmentally conscious company and has been taking initiatives in social forestry for the past several years and promotes farm forestry in its surrounding areas. In an interview with Paper Mart, Mr. Pavan Khaitan, Managing Director, Kuantum Papers Ltd. reveals more about the company’s social and farm forestry programmes.
Paper Mart: Please tell us about your pro-afforestation schemes. How much area is covered under plantations by you? Pavan Khaitan: The social farm forestry initiative was started at Kuantum Papers Ltd. in the year 2008. Since then, we have constantly worked on upgrading our own Clonal Propagation Centre (CPC), which now has a production capacity of around 10 lakh saplings per annum. At present, we have covered 3300 acres around Hoshiarpur in Punjab while we have our own plantation spread in 110 acres within the plant premises.
64 | www.papermart.in / February-March, 2022
PM: Tell us about the hardwood and softwood trees grown by the mill. Do you think that sourcing wood from farm forestry is a win-win situation for both mills as well as farmers who want a steady source of income? PK: As a part of the farm forestry initiative, we produce Eucalyptus clonal saplings and distribute the same at very nominal prices amongst the farmers of the surrounding areas. Our plantation team also educates the farmers about inter-cropping, soil preparation, alignment and spacing of saplings and optimum irrigation levels to ensure that they have a good yield.
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We have covered 3300 acres around Hoshiarpur in Punjab while we have our own plantation spread in 110 acres within the plant premises.
From the paper mills’ perspective, farm forestry provides a sustainable source of raw material, which in present times, is a major area of concern. From the farmers’ point of view, they get an additional source of income from the same parcel of land and their risks are also reduced due to crop diversification. This is an additional income source for the farmers, and they can earn anywhere between INR 18,000 and INR 20,000 per annum per acre of land. Thus, farm forestry is truly a win-win strategy for the paper industry as well as the farmer community.
PM: Do you think that India’s agroforestry policy is a step in the right direction? How do you think the recent announcement of policies and legislative changes to promote agroforestry and private forestry in Budget 2022 will help? PK: The announcement of the agroforestry policy in budget 2022 is a shot in the arm for the pulp & paper Industry. The industry is passing through
challenging times in terms of constraints in the availability of wood raw materials. The promotion of agroforestry in the huge reserves of available degraded land which can easily be afforested is indeed a step in the right direction by the government. During budget 2022, the Finance Minister, in her speech, has allowed agroforestry in 25 lakh hectares of land, which shall go a long way in ensuring raw material security for all the woodbased industries. For the last many years, the paper industry has already done plantations on 12 lakh hectares of land. Policies and legislative changes to promote agroforestry in additional 25 lakhs hectares of land shall provide employment to at least 10-15 lakhs persons, supplement the income of farmers, increase the country’s green cover, provide environmental benefits and also generate raw material for all the woodbased industries at competitive rates.
PM: Have you been able to improve the productivity of degraded lands, control soil erosion, and push moisture
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conservation through your social farm forestry program? PK: We constantly educate the farmers on the management of soil fertility to ensure adequate availability of micronutrients, moisture conservation measures and optimum irrigation. Many of the farmers who connected through our plantation program have reported an improvement in the soil quality and thus an overall improvement in the productivity of their lands.
PM: What are your company’s future targets in farm forestry? PK: We plan to expand our clonal saplings production to 1 crore saplings per annum in the next 5 years to promote and support our farm forestry Initiative. Further, we are also strengthening our plantation team so that the reach of our farm forestry program becomes wider and we are able to connect with more farmers at the grass-root level.
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Star Paper Mills: Social Forestry Activities for Wood Generation Ten Times the Annual Consumption
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tar Paper Mills Ltd., established in 1938, is an integrated pulp and paper mill. From 6000 MTPA to 75000 MTPA, Star Paper Mills has come a long way. It produces a wide range of industrial and packaging papers catering to almost all segments of consumers. For the sustained availability of fibrous raw material, a massive ‘Social Forestry Programme’ was initiated in the year 1996-97 by the company with a distribution of around 1 million seedlings amongst the farmers for planting on their farmland. Today, the area covered under plantations is around 25000 hectares. Paper Mart interviewed Mr. Madhukar Mishra, Managing Director, Star Paper Mills Ltd. to know more about the journey.
Mr. Madhukar Mishra, Managing Director, Star Paper Mills Ltd.
We are consuming around 3 lakh MT of wood and plywood waste per annum whereas we are now supplying clones and seed sapling for plantation in around 25000 hectare area generating 35 lakh MT of wood per year.
Paper Mart: Please tell us about your pro-afforestation schemes. How much area is covered under plantations by you and what percentage of raw materials do you procure from social farm forestry? Madhukar Mishra: Realising the need to have an assured sustainable supply of raw material, Star Paper Mills Ltd. made a humble beginning by encouraging farmers to plant Eucalyptus in their fields in our nearby areas. The area has gradually been expanded to Saharanpur, Muzaffarnagar, Bijnore, Moradabad JP Nagar, Haridwar, and Dehradun. Beginning in 1996 with the distribution of 1 million Eucalyptus seedlings, the activities were accelerated and expanded with the enthusiastic participation and response of farmers and we now distribute approximately
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35 million saplings each year in a mix of clonal and non-clonal. The high-yielding clones are produced in our high-tech nursery. Our emphasis is to increase the productivity of renewable wood resources to benefit the farmers and to increase the productivity of wood per hectare. The plantations raised with Eucalyptus seedlings are having an average yield of 70 MT per hectare in a 5-year rotation whereas plantations raised with Eucalyptus clonal plants give a yield of more than 200 MT in the same interval of time. For this, we have developed a Research & Development centre, where we started the development and production high-quality, and high-yielding clonal plants of eucalyptus and poplar. We have also initiated a project for selection and hybridisation and developing still better yielding clones with better pulp properties which shall benefit all the stakeholders. CPPRI and FRI are our partners in this project which is partially funded by the government through cess funds. Our farm forestry program also generates rural employment and the benefit goes to landless labour and small farmers in the catchment area. Besides employment generation in harvesting and transportation, producing value-added products from the harvested trees also enhances local economic activity. We are consuming around 3 lakh MT of wood and plywood waste per annum whereas we are now supplying clones and seed sapling for planta-
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tion in around 25000 hectare area generating 35 lakh MT of wood per year. Our social forestry activities for the generation of wood are more than 10 times and much surpassing our annual consumption.
PM: Tell us about the hardwood and softwood trees that are grown by the mill. Do you think that sourcing wood from farm forestry is a winwin situation for both mills as well as farmers who want a steady source of income? MM: Star Paper Mills promotes Eucalyptus and Poplar as hardwood plantations among farmers by developing and distributing planting materials. The main objective of agroforestry is to increase farmers’ income & sustain the supply of wood to mills in a winwin situation. Enhancement of wood availability through social forestry has led to the development of plywood and particleboard industries in the area thus improving economic prospects for farmers.
PM: Do you think that India’s agroforestry policy is a step in the right direction? How do you think the recent announcement of policies and legislative changes to promote agroforestry and private forestry in Budget 2022 will help? MM: India’s agroforestry policy is helping farmers to grow tree crops to increase their income. Farmers also get a handsome amount after around five years to meet their special one-time expenses. However, government policies have not percolated to the grass root levels and much is needed to be done by field staff to achieve its objectives. There is also a need to facilitate captive plantations so that paper mills can procure material at prices comparable to global peers.
PM: Have you been able to improve the productivity of degraded lands, control soil erosion, and push moisture conservation through your social farm forestry program? MM: In our catchment area, there is practically no degraded land. The agroforestry model is helpful in soil conservation, moisture retention, conserving biodiversity, and environmental amelioration besides rural employment generation. It has also led to a significant increase in green cover
PM: What are your company’s future targets in the area of farm forestry? MM: There is a continuous improvement in our plantation program and we have planned to further increase the capacity of our clonal facility besides working on evolving improved clones. www.papermart.in / February-March, 2022 | 69
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Shreyans Industries: 'Cultivating Eucalyptus Trees Irrigated with our Own Treated Wastewater' Lifecycle of the eucalyptus tree is in between 3-5 years depending upon the variety of saplings. We have been continually planting new plants after each cycle.
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hreyans Industries Ltd. has two paper manufacturing units located at Ahmedgarh and Banah in Punjab. Incorporated in 1979, the agrobased paper mill utilises a wide mix of raw materials including – wheat straw, sugarcane residue, and sarkanda. Currently, the combined capacity for the manufacture of writing and printing paper stands at 94,000 MTPA. Back in 1992, the company had proposed to plant more than 50,000 trees. Today, Shreyans Industries has covered more than 200 acres of land in both the units for utilisation of treated effluent water for plantation of Eucalyptus trees. In an interview with Paper Mart, Mr. Rajneesh Oswal, Chairman & Managing Director, Shreyans Industries Ltd. talks in detail about the trees grown and the technology used.
Paper Mart: How much area is covered under plantation by you? Rajneesh Oswal: We have around 100 acres of land both inside and outside of mill premises where we have planted eucalyptus trees as per the Karnal Technology which is irrigated with our treated wastewater.
PM: Tell us about the hardwood and softwood trees grown by the mill. RO: We are cultivating eucalyptus trees (hardwood) irrigated with our own treated wastewater. However, the plantations are not for our own use as our paper mill is an agro-based mill using raw materials like – wheat straw, sarkanda, and bagasse. We buy the raw material directly from the farmers/sugar mills.
PM: Have you been able to improve the productivity of degraded lands, control soil erosion, and push moisture conservation through the plantation? RO: In Karnal Technology, plantation is done on the leveled field. In this way, the treated wastewater is always present in the furrows which helps retain the moisture in the soil.
PM: What is your company’s future target? RO: The lifecycle of the eucalyptus tree is in between 3-5 years depending upon the variety of saplings. We have been continually planting new plants after each cycle.
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Yash Pakka: Goal to Plant 10 Million Trees a Year ash Pakka Ltd. provides agri-residue pulp in both bleached and unbleached varieties. The company, ever since its incorporation, has supported farming by using bagasse as the major raw material and biofuel husk as the feed for power generation. It has tied up with sugar mills for fulfilling its raw material demand which constitutes 90-95 percent utilisation. While the company does not depend on wood for pulp, it plants trees as a part of its regular activities. In an interview with Paper Mart, Mr. Jagdeep Hira, Business Head, Yash Pakka Ltd. talks in detail about the trees grown and the future targets.
Paper Mart: Tell us about the trees grown by the mill. Mr. Jagdeep Hira, Business Head, Yash Pakka Ltd.
We are a company to plant trees and not cut, but we see this as a necessary investment in the future as a safeguard against raw material and fuel availability.
Jagdeep Hira: Yash Pakka uses bagasse as raw material. The mill is into plantations of over 2 million in a year. At this time, we don't cut any of them for our use. We are one of the companies to plant trees and not cut them, but we see this as a necessary investment in the future as a safeguard against raw material and fuel availability.
PM: Tell us about the hardwood and softwood trees grown by the mill. JH: The tree we plant currently is a eucalyptus clone.
PM: Do you think that India’s agroforestry policy is a step in the right direction? How do you think the recent announcement of policies and legislative changes to promote agroforestry and private forestry in Budget 2022 will help?
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The recent announcement of policies and legislative changes to promote agroforestry and private forestry in Budget 2022 is indeed a great idea to support an economical cost of production. JH: The recent announcement of policies and legislative changes to promote agroforestry and private forestry in Budget 2022 is indeed a great idea to support an economical cost of production. Less dependency on imported raw materials would certainly lead to self-sustenance and price competitiveness. This would in turn as well have a larger green cover in India, providing a clean environment and source of earning at large.
PM: Have you been able to improve the productivity of degraded lands, control soil erosion, and push moisture conservation through the plantation? JH: Particularly not, as our dependence on wood as a business is nil, still as a mission we have been aggressively working on pond restorations in the nearby localities.
PM: What is your company’s future target? JH: Our goal is to plant 10 million trees a year.
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ITC PSPD
Embarking upon Digital Transformation to Achieve BottomLine Benefits & Operational Excellence
We are constantly exploring opportunities to add capacities in the current machines and through new machines at our factories.
Mr. Vadiraj Kulkarni, Chief Executive, ITC Ltd. – Paperboards & Specialty Papers Division
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TC’s Paperboard & Specialty Papers Division (ITC-PSPD) is known for its continuous steps in the realm of innovative ideas and ground-breaking technologies. Recently, the largest paper and paperboard company in India expanded one of its paperboard machines at its Bhadrachalam unit by around 50000 MT. Not only this, but the unit has also got a modern state-of-theart recovery boiler that happens to be significantly larger than the boilers previously delivered to India. The recovery boiler represents a new era in Indian recovery boilers and has high power features that enable the mill to increase its energy production. In an interview with Paper Mart, Mr. Vadiraj Kulkarni, Chief Executive, ITC Ltd. – Paperboards & Specialty Papers Division, talks more about such developments along with industry 4.0 initiatives taken by the company.
Paper Mart: ITC-PSPD has expanded one of its paperboard machines by around 50000 MT in the year 2021-22. Tell us more about this project. How will the expansion help in driving competitiveness and growth? Vadiraj Kulkarni: The expansion of capacity for virgin paperboards at our Bhadrachalam Plant has enabled us to sustain our market share in the growing segment. The expansion has also helped us further improve the product quality on this machine. The additional capacity has helped us to feed the growing export market.
PM: Please share details about your mill modernisation and mill expansion projects. VK: The pulp mill modernisation and upgrade project is progressing well and is on time, despite COVID-19 disruptions in the second and third waves. We are constantly exploring opportunities to add capacities to the current machines and through new machines at our factories.
PM: A new recovery boiler was installed at Bhadrachalam Pulp Mill which happens to be significantly larger than other boilers. Tell us more about the distinct features of this boiler along with its advantages.
largest pulp and paper/paperboard mill at Bhadrachalam. The 2700 tonnes of dry solids per day capacity boiler, designed, and built in Finland and India, boasts of high energy to renewable fuel ratio and global benchmark in emission standards. The boiler is part of the INR 1920 crore project comprising pulp mill capacity upgrade and the new boiler. At full capacity utilisation, the project will save 1.50 lakh tonnes of coal, thus contributing to greener manufacturing.
PM: ITC has always been at the forefront of digital adoption. Kindly elaborate on some of the industry 4.0 initiatives taken by your company.
VK: In line with its triple bottom line philosophy, ITC has commissioned a state-of-the-art high-efficiency recovery boiler (the largest in the country) to replace three medium and smallsize recovery boilers at the country’s
VK: ITC PSPD has embarked upon a comprehensive digital transformation program to achieve significant bottom-line benefits and operational excellence. These include manufacturing, pulp-wood plantations, procurement, sales and marketing,
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The 2700 tonnes of dry solids per day capacity boiler, designed and built in Finland and India, boasts of high energy to renewable fuel ratio and global benchmark in emission standards.
The multi-dimensional digital interventions encompass industrial IoT for smart operations, integrated data infra/platform, AI/ML algorithms for ‘Golden Batches’ in the process, AI/ML-based image analytics, IoTbased crop monitoring & advisory.
sustainability, finance, IT, HR, logistics, etc. It is also collaborating with partners from start-up ecosystems, as well as established solution providers, in building solutions custom-fit to business requirements. These interventions got a significant boost amid the COVID-19 pandemic, which provided further impetus to step up digital transformation. Over 50 use cases have been developed and implemented across various spheres of the business and enabled PSPD to expand its margin by 230 basis points over the last two years. Paperboards’ business division is leveraging digital technologies such as IoT, advanced analytics, and image analytics to strengthen its leadership position in the global pulp, paper, and paperboard sector. The multi-dimensional digital interventions encompass industrial IoT for smart operations, integrated data infra/platform, AI/ML algorithms for ‘Golden Batches’ in the process, AI/ ML-based image analytics, IoT-based crop monitoring & advisory.
integrated mechanical and chemical pulp mills helps us reduce the impact of external market dynamics. Having said that, ITC has strong inventory norms for various imported items, thus helping us tide over the crisis quite well.
PM: The biggest challenge faced by the Indian paper industry is the uncertainty regarding the availability of uniform raw materials. How do you cope with raw material supply chain issues, price volatility, and import challenges?
We have also diversified our sources geographically which reduces the impact of unforeseen events in one geography. Price volatility has hit the entire value chain of the industry, so the only way to deal with it is to have tight control on costs and build structural cost advantages for the medium to long-term.
VK: While this has been a challenge for the last one year, our strategy of backward integration in terms of raising plantations for wood security,
PM: What steps have you taken to increase in-house pulp production? Also, shed some
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light on the strategic changes implemented by ITC. VK: Our both pulp mills – mechanical and chemical are fully utilised. We have been able to increase the capacity of the pulp mills through frugal innovations and digital interventions. Our project on upgrading and modernising both pulp mills is underway and on schedule.
PM: Is there anything else you wish to add to the interaction? VK: The industry would face challenges in ensuring the availability of wood (for integrated mills) in the future. So, I urge the wood and fiber-consuming mills to scale up plantations program in their respective catchment areas.
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Innovation is the Growth Mantra of ITC-PSPD We are unique in the paper packaging and print field in the manner in which we identify a new opportunity, do a deep dive, assess the worth, assemble a team and then create prototypes and deliver a product which very often creates a new market or adds value by substitution.
Mr. S.N. Venkataraman, Executive Vice President-Marketing & Commercial, ITC-PSPD
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TC’s Paperboards and Specialty Papers Division is India’s largest, technologically advanced, and most eco-friendly paper and paperboard company. It is the leader in volume, product range, market reach, and environmental performance. With businesses catering to a wide spectrum of packaging, graphic, communication, writing, printing, and specialty paper requirements, the company is the market leader in the value-added paperboards segment. Over the years, ITC-PSPD has developed several new products and variants to meet specific industry & customer needs. This has resulted in an enriched range of products offering superior solutions to a wide cross-section of customers. Paper Mart interviewed Mr. S.N. Venkataraman, Executive Vice President-Marketing
& Commercial, ITC-PSPD, to know about the recent achievements of the company with regard to product development, market growth, and application areas.
PSPD as an organisation has always strived to ensure that our products should be manufactured in the most sustainable manner and should have the least impact on the environment.
Paper Mart: Could you shed some light on the new developments at ITC-PSPD with regard to product development, market growth, and application areas?
Our team has been working diligently to cater to this increasing demand for plastic substitution products and has developed various alternatives to single-use plastics. Recently, we have launched our ‘Filo’ series of paperboards that come with a special barrier coating that gives excellent oil, grease,
S.N. Venkataraman: Currently, our focus is on ensuring that we retain product leadership in the domestic market, developing a host of sustainable alternatives to plastic packaging, expanding in our core business, identifying and creating new platforms for growth, which are adjacencies to our main business, and keep improving the sustainability and carbon footprint of our products. The recent intensification in regulations by global and national agencies to minimise plastic waste, coupled with the increasing awareness among consumers about the importance of sustainability, has created a significant demand for plastic alternatives in the market. To add to that, ITC
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The ‘Wrapwell’ series of paper is also being energised to cater to the food wrap segment… they are 100 percent recyclable under standard recycling systems, as opposed to LDPE/BOPP coated paperboards. and water resistance for various applications in the F&B industry. The ‘Wrapwell’ series of paper is also being energised to cater to the food wrap segment. The most interesting part about this series of products is that they are 100 percent recyclable under standard recycling systems, as opposed to LDPE/BOPP-coated paperboards. In addition, we are working along with some of the leading e-commerce players in the country to help them reduce their plastic packaging consumption. For this, we have recently developed a specialty ‘Tough Pack’ paper which acts as a direct replacement to single-use plastic packaging in the e-commerce Industry. We are tapping into the larger ecosystem which is driven by changing consumer and brand packaging perceptions on consumption, health, and environment, climate change mitiga-
Trends after COVID-19 and the PLI programme of the government will lead to relocation and creation of more manufacturing capacities in India, which will give a boost to the packaging industry.
tion, emphasis on higher recyclability and circularity, and increasing use of digital tools and technologies to manage supply chains and logistics.
PM: ITC has launched antifungal soap packaging paper to replace single-use plastics. How is the product relevant considering its overall environmental impact? SNV: Traditionally, beauty and toilet bar soaps having a certain moisture level have secondary packaging made up of paperboard and primary packaging made up of plastic which protects the soap from any fungal growth and prevents discolouration. In order to eliminate the need for primary plastic packaging, we developed a special paperboard with anti-fungal properties. This innovation has helped leading soap manufacturers in the country to significantly reduce plastic consumption in their packaging and meet their sustainability targets, without compromising on the product integrity.
PM: How cost-effective and efficient is paper packaging as compared to single-use plastics? SNV: If one were to view through the existing prism of cost per 1000 packs, the existing division between paper and plastic use would continue. If we were to add costs of littering, segregation, recovery, and final disposal, the picture would wing to paper in many
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applications. I think paper cups and disposables are excellent examples of reducing plastic usage and litter. But for the most effective fiber recovery, the recycling infrastructure should support a quick wash and transport to paper mills. In the case of laminate structures, the paper has a low share based on limited or nil shelf-life and there is scope here for developing paper-based laminates and reducing plastic intensity. Also, the packaging machinery, which so far was used to convert plastic materials, will have to make certain modifications to adapt to paper-based materials. We are working on a few projects and will soon be able to share some developments which can reduce single-use plastics. Beyond the pack’s lifecycle, paper is the only material that can mitigate carbon footprint and that doesn’t enter the equation presently. For all those interested in improving the sustainable performance at a brand/SKU/pack level, I refer you to the new CII GREEN PRO which is a holistic standard developed by CII Green Centre. One can refer to the website for more details.
PM: How does the market and consumer feedback process play an important role in the R&D of such products in ITC? SNV: We are unique in the paper packaging and print field in the manner in
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We have several firsts; cigarette and liquid packaging boards which even now our competitors are struggling to perfect in India, the ‘High Bright’ series of papers as showcased by our Alfa Plus and the entire portfolio of packaging boards from Cyber XLPac, Carte Lumina to our Inobarr and Indobev.
which we identify a new opportunity, do a deep dive, assess the worth, assemble a team and then create prototypes and deliver a product which very often creates a new market or adds value by substitution. We were the first to integrate print and packaging professionals into our larger marketing and product development teams. We have several firsts; cigarette and liquid packaging boards which even now our competitors are struggling to perfect in India, the ‘High Bright’ series of papers as showcased by our Alfa Plus, and the entire portfolio of packaging boards from Cyber XLPac, Carte Lumina to our Inobarr and Indobev. In the last 2-3 years, our teams have responded, even in these pandemic times, in developing and launching the ‘Filo’ series, heat-sealable papers, newer ice cream packaging, Indobowl for takeaway foods, anti-microbial/ viral papers, etc.
PM: What kind of market trends do you expect in the coming months, and how do you see the packaging sector developing in the long-term? SNV: In the near term, the industry and its customers have to
navigate the challenges posed by supply-chain disruptions, escalating costs, and challenges in the availability of raw materials and other inputs. Trends after COVID-19 and the PLI program of the government will lead to relocation and creation of more manufacturing capacities in India, which will give a boost to the packaging industry serving especially pharmaceuticals, consumer entertainment products, apparel and processed foods. Looking at the recent regulations on plastic waste and the inclination of state governments to ban single-use plastics, combined with the growing consumer inclination to opt for more eco-friendly alternatives, the demand for plastic substitution products is going to witness an upward trend in the coming days. We are also noticing a surge in demand for FSC-certified paper products, as this helps packaging buyers ensure that their raw materials are coming from sustainable sources. It is likely that there will be more PE interest in the folding carton packaging business and a steady double-digit growth looks feasible.
Looking at the recent regulations on plastic waste and inclination of state governments to ban single-use plastics, combined with growing consumer inclination to opt for more eco-friendly alternatives, the demand for plastic substitution products is going to witness an upward trend.
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PM: In an earlier interview with ITC, we came to know that the company has developed antiviral paper for applications in the pharma and stationery business. How do you think it will help the pharmaceutical and education sector? When are you planning to commercialise the product? SNV: We have already commercially launched ‘NPP Pro’ under our Protego series of products. This specialty paper has significant anti-bacterial and anti-viral efficacy. It can be used for different applications like printing pharmaceutical leaflets, packing cutlery in restaurants to avoid surface transmission, etc.
PM: Amid the drop in COVID-19 cases, schools and offices have started re-opening, how do you foresee the trend for writing & printing papers in the future ahead? SNV: The school & college stationery and publishing markets are the main drivers for consumption. We have already started witnessing an uptick in demand for the writing & printing paper segment. The use of office papers will also increase. We expect this demand to increase significantly in the coming months, as no inventory was maintained for these products in the supply chain during COVID times, and some capacity got diverted to cup stock manufacturing. Demand destruction has mainly occurred in the cultural segments of diaries, annual reports, and calendars, but then opportunities are opening up for grocery bags, paper straws, food packaging, and due to regulatory requirements in labelling.
E•V•E•N•T C•O•V•E•R•A•G•E
IPPTA holds 56th AGM & Seminar Emphasising on Best Practices in the Industry The seminar was organised on 25 and 26 March 2022 at The Leela Ambience Convention Hotel, Delhi.
Sharing and implementing best practices is an excellent way to help businesses improve their products and maximise the value of investments. After two years of the pandemic, when the paper industry is still witnessing a recovery, the Indian Pulp and Paper Technical Association (IPPTA) hit the right chord by holding a seminar on the theme of ‘Best practices in the field of manufacturing, environment, HR Image building and branding by pulp & paper industry’ during its 56th Annual General Meeting on 25 and 26 March 2022 at The Leela Ambience Convention Hotel, Delhi. With the inaugural session setting the tone of the seminar, panel discussions and technical sessions covered many salient
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topics in depth. The discussions revolved around the emerging challenges & opportunities for paper & allied industry, branding & HR, and energy efficiency. Although the meeting was organised in physical form after two years of gap, it was well attended with each session witnessing a full house. The event commenced with a lamp lighting ceremony by the Chief Guest, Mr. Pawan Agarwal, Managing Director at Naini Papers Ltd. in the presence of Mr. Raghavendra Hebbar, Chairman–Programmer Committee Business Development, JK Paper Ltd., Mr. M.K. Goyal, Honorary Secretary General, IPPTA, Dr. Ashok Kumar, Executive Director, Pudumjee Paper Products Ltd., Mr. Sanjay Singh, Pres-
E•V•E•N•T C•O•V•E•R•A•G•E ident – IPPTA and Group Head, Paper & Packaging, ITC Ltd. and Mr. Ganesh Bhadti, Vice President, IPPTA and President-Operations, Seshasayee Paper and Boards Ltd. Usually, in an event, bouquets are presented to the dignitaries, but IPPTA deviated from the normal by honouring the dignitaries with ‘Grow Trees’ certificates. While delivering his welcome address, Mr. Raghavendra Hebbar informed about the various arrangements and thanked the efforts of the people in the organising committee. Talking about the current situation, he said that every crisis presents a chance to improve and reflect on how one can improve, preparing oneself for the challenges in the future. “As Winston Churchill said, ‘Never let a good crisis go to waste’, I also think that every crisis is an opportunity. The paper industry is gearing up for the challenges and addressing them. We have a number of issues and opportunities, thus, adopting the best practices will be the key to sustain and succeed.” Mr. M.K. Goyal spoke about the scenario of the paper industry and trends impacting the various segments. He talked about the challenges pertaining to raw materials and emphasised that paying diligent attention to efficiency in manufacturing is the only way one can thrive. Further, he presented the theme of the seminar and introduced the speakers in the sessions.
tion from waste paper,” he said, adding, “Presently, there are a large number of paper mills in our country in various segments. The mills produce roughly 1000 TPD from a single location. Further, there are many single machines that make more than 400 tonnes of paper or paperboard only.” Talking about the progress of pulp-making technologies in the paper industry, he mentions that the country now has a BCTMP mill and all kinds of lines – washers, presses, etc. are there. The consumption of freshwater has reduced drastically due to the advancements made in the technologies used in the pulp and paper industry. With time, the level of brightness in the pulp has increased significantly and there has been a great advancement in the recovery boilers. To bring further improvements in the pulp-making processes, he also suggested that the industry players should come together and strategise how to make the most out of their pulp, whether it is imported or indigenously manufactured. “And the way to do is installing high-tech and sophisticated refiners,” he pointed out. Talking about the present scenario and the development of the paper industry, Dr. Kumar appreciated the improvement in the awareness of the paper manufacturers regarding the specifications and pattern, digital/online wet-end chemistry control of retention, and the advent of alkaline papermaking. There are different categories of mills, i.e. wood-based, recycled paper-based, and agro-based paper mills and in the words of Dr. Kumar, the mills do not compete but ‘complement’ each other. In his presentation, Dr. Kumar also highlighted that the environment-friendliness of mills does not depend only on the processing of the raw material, but also on the technologies being used in the manufacturing. He described the market conditions as “unstable” for some time, concluding that, “the concerns of sustainability and environment would be crucial for the paper industry”.
The paper industry is continually progressing with rapid advancements in the technology being used in various areas along with maintaining a focus on sustainability. Since there will be plenteous challenges along with opportunities, Dr. Ashok Kumar, Executive Director, Pudumjee Paper Products Ltd. (PPPL) began his address emphasising that the industry should reflect upon how can it further improve and enhance its operations. In the last seven years, the industry has initiated efforts like – celebrating ‘Paper Day’, and dispelling the myths about the papermaking industry. Dr. Kumar suggested that school children should be educated about the efforts made by the paper industry in the direction of sustainability. Presenting an account of how the paper industry has evolved in the past four-five decades, Dr. Kumar said that the size of most paper mills previously used to be about 150 TPD or so, and wood or agricultural residues were the only potential raw materials. “We used to depend on hardwood plantations, bagasse, and mostly 70 percent of the produc-
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Mr. Sanjay Singh, President, IPPTA and Group Head, Paper & Packaging, ITC Ltd., while delivering the Presidential Address at the conference, said, “I have been a part of the paper industry for the last forty years and have seen tremendous improvements as well as the challenges in the time.” He also highlighted that the growth in the paper
E•V•E•N•T C•O•V•E•R•A•G•E mills has been tremendous all across, irrespective of their size and scale. “Going forward, I am very confident that the future of the industry is going to be very bright”, he said. With regard to human resources and talent acquisition in the industry, he added, “We will have to acquire more young talent as talent retention is a big issue in the paper industry. We, at ITC, have been undertaking a lot of efforts to retain talent.” Giving a strong emphasis on the need to increase awareness about the sustainable efforts of the paper industry, Mr. Singh pointed out, “While the paper industry has been undertaking a lot of efforts in the direction of environment conservation, we still need to work hard to make people aware about the same.” The lifetime achievement award was conferred to Mr. B.M. Khanna, Founder of Khanna Paper Mills Ltd.
Mr. Pawan Agarwal, MD of Naini Papers Ltd. and also the Chief Guest of IPPTA’s 56th AGM, spoke about various upgrades and technological modernizations that have been introduced in the paper mill, while also taking the audience through the evolution of Naini Papers since its inception. Mr. Agarwal says, “Today, any paper mill, which wants to grow in a sustainable manner, has to take care of its effluent being discharged from its mill. There is no substitute to it.” While the COVID-19 delayed the rebuild of PM2 by slightly more than a year, they were able to commission it in October 2021. He stated, “It (the machine) is running fine and we are getting some wonderful results. In fact, the quality of the paper has totally transformed and we are exporting close to 22 percent of our total production of PM2 to various countries.” “As they say that one should start preparing for a crisis in advance, with the rebuild of the PM1, Naini Papers had prepared for COVID-19 that has been an unprecedented crisis.” Outlining the impact of sophisticated production lines at their unit, he added that they were able to match the quality of absorbent kraft produced from wood because of having a technologically advanced machine. Emphasising the importance of installing systematic water management systems and water conservation practices, Mr. Agarwal stated, “A mill should start preparing for the recycling activities while installing the technologies where one can recycle more and more of its effluents.” IPPTA has been giving awards since 2018 to people who have contributed to the paper industry immensely. This year, the awards were further modified, as the association now presents awards to industry players, entrepreneurs, technology suppliers, and academicians.
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Dr. A.G. Kulkarni, a researcher, and scholar, was awarded in the category of Research & Development. With an experience of forty years in R&D in the pulp and paper industry, Dr. A.G. Kulkarni has spent 28 years (including 10 years as the director) with CPPRI.
Mr. Anil Kumar of Shreyans Industries Ltd. and Mr. S. Ibrahim, Managing Partner of the Globe Radio Company were also given awards for their contribution to the industry. The vote of thanks was delivered by Mr. Ganesh Bhadti, Vice President, IPPTA and President-Operations, Seshasayee Paper and Boards Ltd., to conclude the proceedings of the AGM. “It is really heartening to see the AGM happening in the presence of many stalwarts, industrialists, academicians, professionals, and also the young talent. The last two years have been very difficult and have badly hit us both – personally and professionally. The IPPTA members
E•V•E•N•T C•O•V•E•R•A•G•E have shown their solidarity and the strength to prove that we can come out of many such situations,” he said.
generated in developed countries in Europe, and the USA, where the waste collection is efficient. There is a huge opportunity for the industry to partner with agencies, NGOs, etc. to increase the segregation of waste and improve the collection efficiency.” About the efforts in the direction of sustainability, he concludes, “We, at ITC PSPD, have significantly reduced the consumption of water and energy as well as increasing renewable energy share. And this is a very important area for the industry to work upon.”
The inaugural session was followed by a panel discussion on the topic of emerging challenges & opportunities for paper & allied industry that was moderated by Mr. K.S. Venkatagiri, Executive Director – CII Hyderabad. Talking about the issues, Mr. Vadiraj Kulkarni, Chief Executive, ITC PSPD, said, “In my own assessment, notwithstanding what is happening between Russia and Ukraine, the two years since the advent of COVID-19 has significantly changed a lot of things in a lot of industries including the pulp, paper and paperboard industry.” Since India is a fiber-deficient country, the challenge is to ensure the procurement of wood. Sharing the pertinent solutions to this challenge, he said, “We can make wood available only if are able to work with farmers, increase plantation coverage as well as the catchment areas and the farmers get their due share. Besides, if the industry can partner with the farmers and government schemes, as well as undertake R&D in wood pulp making, which we have been doing for the last many years, we will be able to ensure security in wood supply in the coming years.” Regarding the recycled paper-based mills, Mr. Kulkarni opines, “Coming to the recycled paper or recycled board and recovered fiber, we are heavily dependent on the waste
Panellists of Technical session on Manufacturing & Energy
Presentation of memento to panellists
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Other panellists in the session included Mr. Ashraf Nathani, Partner, Mehali Papers Pvt. Ltd., Mr. Deepak Mittal, President, Federation of Paper Traders Associations of India, Mr. Manish M. Patel, Managing Director, The South India Paper Mills Ltd., and Mr. Sanjay Rajgaria, President, Indian Corrugated Case Manufacturers’ Association. The technical session that followed, was headed by Mr. Neehar Aggarwal, COO, BILT Graphic Paper Products Ltd. and attended by notable speaker Ms. Tanvi Bhatt, Mr. Prabodh Kumar Patra and Mr. Debi Prasad Roy from ITC, Mr. Arjunan P N, Mr. Vipin Raghavan, Mr. Tajinder Bir Singh Chahal, and Ms. Samyukta Sankaralingam from Haber as the panellists. Mr. Ashish A. Gupta, President, Emami Paper Mills Ltd. was the chairman of the second technical session that was on ‘Excellence and Energy’. Some of the panellists included Mr. A Harinarayanan, Mr. K Rambabu, Mr. Chandra Sekar E, Mr. Syam Kiran P. from ITC, Mr. Ganesh Bhadti, and Mr. Radhakrishnan from Seshasayee Paper & Boards Ltd. among others. The second day of the seminar also saw the participation of many stalwarts of the paper industry wherein topics such as manufacturing, energy, environment, logistics, and equipment were discussed. The seminar was concluded with an award ceremony and a vote of thanks by Mr. Goyal.
Panellists of session on Emerging Challenges and Opportunities
Team Paper Mart Directory at IPPTA Event
C•A•S•E S•T•U•D•Y
India Continues to Rise as a Paperboard Powerhouse Fitting with the JK Paper sustainability objectives, AFT has supplied a complete POM® wet end and a refining system. The wet end system includes a full POM approach flow for the multi-layer machine with POMix stock processors, POMp degasser arrangements, and MaxFlow headbox screening. JK Paper Grows its Leadership Role An important 2021 milestone in India’s continuing rise as a paperboard powerhouse is JK Paper Ltd.’s new PM5 cartonboard machine in Fort Songadh, Gujarat. With a capacity of 170,000 TPA, this multi-layer board machine successfully started up at the end of August 2021. PM5 is designed to produce board grades with basis weights ranging from 160440 gsm with an operating speed up to 700 m/min using BCTMP and Kraft fibers. In the words of JK Paper’s President and Director, Mr. A.S. Mehta, “We are proud to produce premium cartonboard grades, doing so with worldclass equipment and highly trained operators. Our strong sustainability commitment is demonstrated by low energy and water consumption for a machine of this size.” Mr. Mehta adds, “We will produce top-quality folding boxboard (FBB) and solid bleached sulfate board (SBS) and convert them
New ADC low consistency refiners treating fibers for FBB and SBS carton products
to meet customer requirements with our modern converting, finishing, and warehousing facilities.” Mr. H.P. Singhania, Vice Chairman and Managing Director of JK Paper, also expresses appreciation
AFT MaxFlow Headbox screen installed on the new PM5
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for the JK team and suppliers for successfully starting up a new board line in extremely challenging times due to Covid interruptions, travel restrictions, and remote commissioning of various equipment.
AFT Stock Prep and Approach Fitting with the JK Paper sustainability objectives, AFT has supplied a complete POM® wet end and a refining system. The wet end system includes a full POM approach flow for the multi-layer machine with POMix stock processors, POMp degasser arrangements, and MaxFlow headbox screening. Basic engineering and mill site services were
C•A•S•E S•T•U•D•Y
Mr. Olli Pekka Riippa, AFT Product Manager - Refiners and Deflakers
part of the AFT delivery. Engineering supply included complete process and plant engineering with 3D modelling. Compared to traditional approach flow systems, the POM paper machine wet end with headbox screening delivers superior stock cleanliness in a compact and efficient package. Without the need for traditional storage tanks, POM runs smoothly with lower water and energy usage for enhanced environmental performance. Operational features of the POM system result in higher board machine operating efficiency and increased annual production capacity.
According to Mr. S.K. Jain, Head of Board Projects, “AFT’s contribution helps us make fast grade changes in a cleaner, short circulation system - with less air and biological build-up to yield fewer sheet defects and breaks, which is best for our multiply operations.” In addition, AFT’s ADC38 double conical refiner design increases production capacity for a single unit, while offering easy access for maintenance and filling changes. The refining process design is flexible and adaptable for multiple fiber types. JK Paper can easily configure the refining system as per fiber type and re-
POMp Degassing keeps air out of the paper machine feedstock, to improve overall cleanliness and maintain high operating speeds.
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High consistency FiberClone Cleaner system
fining requirements needed for their products. Low-intensity refining is achieved with Finebar® conical filling technology for optimum fiber development with low energy use. Notes Mr. Sourav Das, AFT Regional Sales & Marketing Manager – Asia Pacific, “Board properties are significantly influenced by refining. Desired objectives happen almost instantly in combination with the benefits delivered by the compact POM system. This helps of course with grade changes, but also in product optimisation. The commitment to innovation and sustainability at JK Paper is impressive. We do our best when flexibility is important, matched with a long-term focus on doing what is better for the planet.” Mr. Olli Pekka Riippa, AFT Product Manager - Refiners and Deflakers says, “Our cooperation with JK Paper gives us opportunities to push refining to a higher level. Fiber treatment can be optimised to achieve the specific product characteristics that their customers demand. As proven in many installations, the ADC refiner concept saves applied refining power. Preserving energy is one of the main factors for papermakers’ profitability and competitiveness.”
R.S.ENGINEERS
Manufacturers of : • Doctor Blades • Doctor Oscillation Systems • Doctor Holders • Felt Stretchers • Doctoring Systems • Autoguides
Address: Plot No.19, SR.NO.2608, Shanta Gulab Industrial Park, Besides Damanganga Industrial Park, Karvad, Vapi-396193 +91 9898130415, +91 9227830415 Cell: Email: ayaz@rs-engineers.com, sales@rs-engineers.com Website: www.rs-engineers.com www.papermart.in / February-March, 2022 | 95
I•N•D•U•S•T•R•Y S•P•E•A•K
Cheema Boilers: Steaming Ahead to Make Industry Energy Efficient In view of the rising energy demand and related environmental concerns, the paper industry is gradually moving towards alternate and more efficient fuel options. Foreseeing the future, Cheema Boilers Ltd. is continuously upgrading itself technologically. eration cost, the government is issuing tradable energy certification on saving carbon footprints under the Perform, Achieve, and Trade (PAT) scheme. Additionally, the industries are also benefitting from initiatives such as Make in India, the National Manufacturing Policy and the promotion of renewable and clean fuel usage.
Meeting Industrial Requirements in Energy Transition Phase
Author: Mr. Davinder Pal Singh Brar, Director-Operations, Cheema Boilers Ltd.
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ndia’s share in the world production of paper and paperboard is about 2 percent. While it is projected to be 5 percent in near future, challenges with respect to energy cost, capital expenditure, green technologies, and quality improvement to compete in the international market cannot be ruled out. The paper industry is energy-intensive and consumes about 10-14 tonnes
of steam and 1200-1400 KWH power per tonne of paper produced. In order to keep up the pace with other countries, the paper industry in India will need to make efficient use of energy, conserve energy, and switch to renewable resources to meet the increasing energy demand. While the energy generation costs for the industries have increased in terms of capital expenditure and op-
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Cheema Boilers Ltd. (CBL) is contributing to meeting India’s energy goals in this transition phase. With an aim to help the industry reduce steam generation costs and carbon footprints, CBL is continuously developing technology with state-ofthe-art engineering and design facilities. While the company has installed high capacity boilers producing power worldwide in the paper industry, it promotes efficient use of energy with its highly efficient boilers as well as emphasizes using renewable and waste fuels. Paddy straw, the waste product of paddy grown across the country is burnt in the field by farmers which release hazardous gases like carbon dioxide and carbon monoxide. When burnt in bale forms in boilers, paddy straw can generate energy for industrial needs. This waste-to-energy method also results in lesser carbon footprints. Monetarily beneficial both for industry and farmer, boiler ash contains silica and potash con-
I•N•D•U•S•T•R•Y S•P•E•A•K tent which can be used in the construction sector and fields (as manure) respectively. CBL’s reciprocating/pulsating grates type boiler is a solution to use biomass fuels efficiently. The company has developed a highly efficient Water Cooled Vibrating Grate Bale Fired Boiler which runs on multiple fuels like rice straw bale, cane trash, mustard husk, cotton stalk, palm fibre corn cob, wood chips, etc that are abundantly available in India. Besides this, CBL has also developed the technology to generate energy from hydrogen.
Forming Strategic Associations in the Industry Foreseeing the future, CBL is ‘steaming ahead’ to upgrade itself technologically and got into several strategic partnerships. One of the most promising partnerships has been with a prestigious company for the firing of municipal solid waste specifically designed by Horizontal Grate which holds enormous potential in times to come.
CBL is also associated with Nu-way (Enertech Group – UK) for promoting their wide array of highly durable burner ranges qualifying to the most stringent global standards. Besides the
standard gas and liquid fuels, the partnership gives the company an edge to deal with complex fuel combinations with biogas, PNG, hydrogen, etc. along with multi-firing compatibility.
Meet us at Stall No-C18 | Hall No-9 10-13 May | 2022 | India Expo Center, Greater Noida, India
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I•N•T•E•R•V•I•E•W
Pidilite Industries: Strengthening Position in Paper Coloration Products We are a market leader in colorants for writing & printing paper and board manufacturing. This stems from our technological understanding of pigment and dispersion technology, backward integration and ability to work closely with customers for specific developments.
the past 73 years, we have diversified into successful consumer & bazaar of Araldite in Indian sub-continent and B2B businesses. We take pride in being a highly technology-oriented and customer-focused company with a leadership position in most of the categories we participate in. Mr. Rajesh Balakrishnan, CEO-IP Division, Pidilite Industries Ltd.,
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pecialty chemicals company Pidilite Industries Ltd. sustains a strong bond with clean chemistry and its customers across the globe. From a single product to a major manufacturer of premium specialty chemicals, Pidilite Industries has come a long way. It is now India’s market leader in adhesives and sealants serving diverse markets in various parts of the world. In an interview given to Paper Mart, Mr. Rajesh Balakrishnan, CEO-IP Division, Pidilite Industries Ltd., talks about the product portfolio and recent developments that have taken place in the company.
PM: Shed some light on your product portfolio. RB: We offer a range of adhesives, sealants, waterproofing products, art and stationery products, and consumer products for wood-working, schools, construction, automotive and other industries. In the B2B segments, we offer a variety of adhesives for Packaging, transportation, electronics, book-binding, footwear and mattress manufacturing industries. We also offer a complete package of solutions for the textile, paints, construction, leather and allied industries
Paper Mart: Tell us about your company.
PM: Tell us more about the chemicals you manufacture for the pulp and paper industry.
Rajesh Balakrishnan: Pidilite Industries Ltd. started as a company in 1959 with pigment dispersions and our flagship adhesive brand, Fevicol. Over
RB: We are a market leader in colorants for writing & printing paper and board manufacturing. This stems from our technological understand-
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ing of pigment and dispersion technology, backward integration and ability to work closely with customers for specific developments. We also make polymers for board coating applications as well as specialty dispersing agents and thickeners used in the paper industry.
PM: What have been the recent developments in Pidilite Industries Ltd.? RB: We have added more products to our coloration portfolio. These pigment dispersions have superior dispersion properties with the right balance of light and other performance properties. We have also launched a new range of polymers based on a nanoparticle size range for board coating as well as specialty dispersing agents.
PM: What are your future plans? RB: With the growing attention to the elimination of single-use plastic, we are actively pursuing solutions for barrier-coated paper products. We will also strengthen our position in paper coloration products and offer a comprehensive range in the board application in addition to strengthening our international presence.
M•I•N•D•F•U•L•L•Y S•U•S•T•A•I•N•A•B•L•E
Proklean Technologies – Driven by Cost-effectiveness & Sustainability We are completely committed to coming up with a wide range of products for the pulp and paper industry... reducing the pollution footprint of the industry and also helping the industry to save costs.
money for our customers by reducing the usage of basic chemicals like peroxide, chlorine dioxide, and caustic, which also helps us to achieve our original objective of reducing pollution. Dr. Sivaram Pillai, Co-Founder & Director (R&D), Proklean Technologies Pvt. Ltd. (Image Source: IPPTA)
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stablished in 2012, Proklean Technologies is a company based out of Chennai. It was founded to explore industrial applications using probiotics with the core intent of contributing to making the world a better place by reducing pollution and conserving natural resources. Proklean has developed a proprietary technology using a unique combination of probiotics with fermentation and formulation methods. In an interview with Paper Mart, Dr. Sivaram Pillai, Co-Founder & Director (R&D), Proklean Technologies Pvt. Ltd., talks about his journey, product portfolio, and an outlook on the pulp & paper industry.
Paper Mart: Tell us in brief about Proklean Technologies Pvt. Ltd. and walk us through your journey.
Dr. Sivaram Pillai: Proklean was started by me and two other friends about ten years ago with the objective of doing something interesting in the area of probiotics since all of us had a common interest in that subject. Within a year or two, we came up with a very unique way of using probiotics to produce non-toxic and biodegradable surfactant formulations, which could replace the chemical surfactants. We started with the leather industry and moved on to the textile industry. Based on our experience in both these sectors, we entered the pulp and paper industry. We have developed very unique applications in the pulp and paper industry which significantly reduce the use of bleaching chemicals, but at the same time, deliver the parameters required by the customers. We end up saving
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We make sure that anything we develop is sustainable both in the manufacturing process as well as the application. Similarly, anything we introduce commercially should lower the cost of processing for the customers, and at the same time, release less pollution. These are the boundaries that we have set in our journey. We were originally bootstrapped for three-four years, and then took funding from investors, first from a group of angel investors, then, subsequently switched to venture capital funds. Over the last few years, we have been building a professional team and since April 2021 the day-to-day management of the company is managed by this team.
PM: Please elaborate on the product portfolio and the clientele of the company, specific to the paper industry.
M•I•N•D•F•U•L•L•Y S•U•S•T•A•I•N•A•B•L•E
SP: In the pulp & paper segment, we have been able to introduce cooking aids, odour controllers, and bleach enhancers. We have launched ProCook, which is a first-of-its-kind non-foaming cooking aid solution that is readily bio-degradable and non-toxic. The cooking enhancer enhances the cooking process while cutting down mercaptans by up to 50 percent. Lower levels of mercaptan gases translate into reduced corrosion thereby saving on maintenance. So, we have a product that enhances the cooking process and has significantly better functionality than other cooking aids currently used in the pulp and paper industry. Talking about our odour control range, ProEnviro is globally the first-of-itskind formulation developed specifically for the paper industry to control/ eliminate odour from the cooking operation by neutralising mercaptans, sulphides and thereby enhance significantly the environment and hygiene in and around a pulp mill. We have also introduced odour controllers for kraft paper mills. As odour is caused by pathogens, we use good microbes to neutralise and reduce their population. ProSolve+ is a uniform blend of Bio-dispersant along with a consortium of naturally occurring beneficial microorganisms. The exopolysaccharides & other organic acids produced by the probiotic microbes act as a potent biocide thus eliminating biocides and hypo. Within a year, over 25 kraft paper mills have adopted this technology. Prowhite and Probleach are first-of-itskind products for application in pulp
Our R&D team has been working on new products for water treatment based on our core Probiotics platform... we are also developing a bio-masking agent, which will not just mask the bad odour, but neutralise the cause of odour in a sustainable way. & paper processing during the delignification and bleaching stage. These proprietary probiotic formulations are readily biodegradable products meant for diverse stages of bleaching. ProRB is a powerful anti-oxidant with high metal chelating property to inhibit iron from impairing the function of Hydrosulphite while the anti-oxidants enhance the reduction efficiency. We have recently launched a product for control of stickies which is again giving good results and getting appreciation from the customers. Pitch control is another important application for both bagasse and hardwood-based paper mills and we have launched a few products in this segment that have started giving good results. Slime reduction is another demand for the industry. We have introduced a product which achieves good slime control for the writing & printing segment. We now have over 35 customers in the pulp and paper industry across bleaching enhancers, deinking, and other products. We serve many large companies as well as medium-scale enterprises including ITC PaperBoards & Specialty Papers Division, Century Pulp and Paper, APL, West Coast Paper Mills, and Tamil Nadu Newsprint and Papers Ltd. (TNPL).
PM: Tell us about your upcoming products. Do you have any products for water treatment as well? SP: Our R&D team has been working on new products for water treatment based on our core Probiotics platform and one such product that would soon be commercialised is bio-flocculant for reducing the sludge. We are also developing a bio-masking agent, which will not just mask the bad odour, but neutralise the cause of odour in a sustainable way. We have formed a separate research team now, with experienced people from the pulp and paper industry. We have a senior scientist with a chemistry and biotechnology background. Our goal is to cover the entire spectrum of the pulp and paper industry in terms of process, except the finishing applications.
PM: What are your USPs? SP: The manufacturing process of our products has a very low carbon footprint as we carry out the fermentation in ambient conditions without any heating or cooling. Usually, the downstream purification process in fermentation-based manufacturing is highly energy-intensive and it releases a lot of effluents. We have completely eliminated the downstream processing, which saves significant energy as well as releases zero pollution. Also, the products are readily biodegradable and non-toxic. Overall, we practice a circular economy by using raw materials which are sourced from nature, using a low carbon footprint manufacturing process to make readily biodegradable products that go back to nature! Typically, green products are not used that much, because they tend to be
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M•I•N•D•F•U•L•L•Y S•U•S•T•A•I•N•A•B•L•E
more expensive than chemical solutions. In our case, we have been able to match the costs due to an innovative low-cost manufacturing system. Therefore, the customer is willing to try our products, which while being cost-competitive, also provides green benefits.
PM: What is your outlook on the paper industry and your future plans? SP: As I mentioned, we are completely committed to coming up with a wide range of products for the pulp and paper industry. We believe that we can contribute significantly both in reducing the pollution footprint of the industry and also helping the industry to save costs. We have set up a separate section in our R&D lab for paper product development. We will be coming up with more and more products for the industry.
PM: In what ways do your solutions assist the paper industry in addressing the crucial parameters like cost reduction, better quality, and enhanced efficiency? SP: We have been able to make a mark in the industry in a very short span of time due to two reasons: The products and solutions we offer to our consumers help in reducing costs. For example, a large paper industry player purchased our bleach enhancer, and with this, they are able to reduce their process costs by INR 50 per tonne, after paying for the cost of our product. That is a significant cost reduction if we consider the large volume of pulp processed by this mill. Second, our products enable the customers to reduce their pollution footprint, that is, reduce the pollu-
We make sure that anything we develop is sustainable both in the manufacturing process as well as the application. tion load/COD load, which helps the industry to further reduce the costs of processing. For instance, for a large mill proposing to invest a significant amount of capital in treating their effluents, if their effluent load is reduced, the effluent treatment costs also come down. Overall, our products save costs and deliver excellent results. We do not compromise on results as far as the customer is concerned.
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T•E•C•H•N•O•L•O•G•Y W•A•T•C•H
BTG dataPARC – Building Intelligence from Process Data A comprehensive solution for plant information management, analytics, and data modelling can help faster troubleshooting and informed decision-making. Importance and Challenges with Process Information Management System The key to efficient manufacturing decisions as well as the core of Industry 4.0 lies in manufacturing data. Collecting it at higher frequencies, keeping it for longer, from more sources, and more points in each process area are most critical in this effort. However, to add value to all this data, you need a robust way to make it available to personnel at all levels to support process optimisation and real-time decision-making at speed of thought and in a format that is easily understood and practiced. Most data visualisation, lab, or analysis software comes with its respective storage systems, but cannot connect to other systems, and is often localised to limited points of use. This is referred to as a data silo and is a big problem in all industries, especially pulp and paper. With multiple distributed control systems, programmable logic controllers, quality control systems, and laboratory systems (to name a few) present in many mills,
all of which use different programs and terminals that are often accessible by a select few people, how does one correlate all this invaluable data?
Handling Data from Multiple Sources The solution is an application that can connect to multiple different data sources and make them available all in one system which is able to be deployed company-wide. BTG’s dataPARC software suite, which is a historian and data visualisation solution designed to connect data across a mill or even a group of mills and make it available in one application is the solution. With all this data available in one place, trends, reports, graphics, centerlines, and other displays that can be used by people at all levels in the mill to make production, optimisation, and troubleshooting decisions becomes simple to produce. Most importantly, such software creates a data standard so you can rely on the fact that everyone is looking at the same analysis. This is pivotal for digitalisation – to integrate data
across multiple sources and mill areas, there must be trust in the data itself. Software like dataPARC helps create this trust through standardising access to data.
What’s Next after Storing Data? Having the collective data readily available in a common, accessible location is important for effective usage, but just the ability to see the data is not enough. You need a strong visualisation and analysis tool to support good decisions with all the newfound data. This functionality is also an integral piece of the dataPARC software. dataPARC has the ability to provide process reports and graphics to enable managers and supervisors to stay current on process conditions and reports. Other management benefits are realised by operations use of the data. Having fast & easy advanced analysis of data from multiple data systems enables a reduction in process and product variability, the ability to proactively make changes, and improved transfer of information between shifts and to management. dataPARC also aggregates operational data based on the above-monitored conditions and time periods, as well as predefined time periods. Daily, hourly, and minutely aggregations make data retrieval speeds for large time periods among the best in the industry, even when using a slower third-party historian.
dataPARC’s Unique Value Proposition - Information to Intelligence Enabling data acquisition and retrieval for quicker and precise
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T•E•C•H•N•O•L•O•G•Y W•A•T•C•H agement, small changes become major impacts when completed strategically and as part of an effective plan for positive digital progress.
Benefits Summary – BTG’s dataPARC Data Management Solutions Senior Leadership Team
decision-making at the speed of thought in the format that you need. Real-time insight into the mill performance and KPIs. Provides a single source of truth for all your manufacturing data. It Aggregates disparate data from machines and manufacturing systems such as DCS, ERP, MES, LAB & Quality systems, to develop the insights that drive continuous improvement. BTG helps it happen irrespective of the make, model, supplier of the data source. Gives your operators, engineers & senior management the power to develop data-driven solutions to your most challenging process issues. BTG helps to create real-time insight into the process connecting high data volume, which is beyond human dimensional thinking. When process issues begin causing downtime or downgraded products, there’s no time to waste. BTG’s high-performance archive engine returns hours, days, months or years of high-resolution data within seconds to help you to troubleshoot and make decisions faster. Give operators, engineers, and the management the insight into current operating conditions using real-time dashboards & displays to monitor equipment status, site-level process flows, or enterprise-wide production KPIs.
ity; which is delayed or complex in the LAB. You don’t need third-party software to perform this task. Economic benefits are achieved by decreasing costs through operational efficiencies enabled with data-driven insights, decision making, and troubleshooting.
Data-Driven Operational Intelligence – Areas of Opportunity in an Organisation If you lack high-performing data acquisition, visualisation, and analytics across your plant or enterprise, achieving it in your manufacturing facility is relatively simple when you employ the right resources and have a plan that allows for gradual changes that add up to significant results. Small changes such as combining existing historian systems, effective software tools, and a mindset of proactive digital awareness for your team can significantly impact the overall success of your operations. Newfound ease in your daily tasks and reporting are results of effective IT/OT convergence and will be experienced by everyone. From the operator to the engineer all the way to corporate man-
Inbuilt modeling capability utilising historical information (static data) to predict difficult process parameters such as Bulk, Tear, Tensile, Freeness, Kappa, Brightness, viscos-
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View on Profitability Help to decide Asset and Resource allocation Unbiased Production / Process Information Key Cost Driver details Enterprise-wide view, not limited to unit operation view Overall Equipment Effectiveness (OEE) On the Go Plant Information access (Mobile) Capable to view process Inventory and interface with other systems like SAP & MIS for order intake Quality Deviation statistics
Manager / Process Engineers Faster Troubleshooting Root Cause Analysis Departmental Efficiency information Inventory view of Pulp / Water / Utility Smart Alarms / Situational awareness Crew Efficiency report Grade / Batch / Reel Analyses Automated Reports
Operators
Live Process Adherence status Smart Alarms Center lining Ontime LAB Inputs
P•R•O•D•U•C•T W•A•T•C•H
Zenith Rollers Launches a New Range of Composite Covers The composite covers – Nanotek and Nanorok have been designed for soft calendars and hard presses, respectively. With features like resistance to wear and chemicals, their use increases the life-span of the calendars along with a number of other benefits for its users.
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enith Rubber Pvt. Ltd. has launched a new range of composite covers in collaboration with Austria-based Skapa e.U., for the soft calendar presses and hard calendar presses respectively. Nanotek has the ability to withstand exacting working conditions for the soft calendar presses including – soft calendar, super calendar, multi-nip calendar, and mat on line calendar. Thus, it makes for a great choice of composite covers. Since the raw material used and the method of manufacturing results in an exceptional quality of finishing, there are no differences in surface texture or in processing paper. Due to low level of porosity of Nanotek, achieving excellent surface finishing is albeit easier. Moreover, the cover has excellent wear resistance ensuring the durability of the calendar. The other interesting product – Nanorok is a composite cover for hard presses, which can also operate effectively in the most demanding operative conditions. It is recommended for a range of presses, including – hard press (wet environment),
Image Source: Zenith Rollers
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central press, hard-size press, and shoot press. The raw materials used as well as the efficiency in manufacturing enables the user to get a very good finish in their products. With this cover, all types of blades can be used while the life span is also increased and the good condition of the surface roughness and the press is maintained. Moreover, Nanorok is resistant to a number of chemicals which are commonly used in the pulp, paper, and paperboard industry, including – alcohol, acetone, acid chemicals, etc. It is also resistant to short exposures of oil and diluted caustic solutions. Endowed with the ability to improve resistance to abrasion, it can significantly increase the lifetime of the presses. With its plants at Noida, Neemrana, Vapi, Ahmedabad, Bengaluru, and Vietnam, Zenith Rubber Pvt. Ltd. has been supplying indigenously manufactured rubber rollers to the industry for more than 40 years. For more details, visit Stall No. 10 – F02 at Paperex 2022.
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BTG Brings FiberMAX for Profitability by Focusing on Mass Flow Variations in Paper Industry FiberMAX features a thorough survey of all furnish consistency control positions, which are based on a holistic view of the process.
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TG has brought FiberMAX, which is a diagnostic service to identify opportunities for reducing fiber cost and variability, including stabilising paper quality for paper manufacturers. During the papermaking process, the control loops for fiber mass flow hold key importance for stable production and operations. In FiberMAX, a thorough survey of all furnish consistency control positions, which are based on a holistic view of the process, is included in the system. Parameters like process measurements, sampling and calibration, and control loop performance are being evaluated and compared to best-practice benchmarks. In order to present detailed recommendations for improvements, the FiberMAX team identifies the sources of variability. Moreover, since FiberMAX is a flexible diagnostic tool, the system is applicable for any type of paper production line and paper grade.
In the past years, FiberMAX has been deployed in a number of pulp and paper mills across the globe. The system has proven to be a very valuable starting point for many improvement proj- BTG FiberMAX system ects, including Industry 4.0. Switzerland-headquartered BTG Group is a multinational provider of integrated, highly specialised process solutions for the global pulp and paper industry. The company assists the pulp and paper manufacturers in achieving sustainable gains in business performance with their technology-centric solutions.
POSITIONS: • Export Manager
for International Market
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Junior and Senior Level For Selling All Grades of Paper and Paper Board. West, East, South India
Corporate Office: C-107, Sector - 2, Noida - 201301, Uttar Pradesh, India | Tel: +91 120 4659700
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Archroma Launches New PFC-Free and AmmoniaFree Cartaseal® VWAF Barrier for Paper-Based Food Packaging Cartaseal® VWAF by Archroma brings increased potential for compostability, repulpability, and recycling compared to PFC and plastics since the coating breaks down with the paper during the recycling process.
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rchroma, a global leader in specialty chemicals towards sustainable solutions, has introduced Cartaseal® VWAF, a new industry-leading perfluorinated compound (PFC)-free and ammonia-free barrier coating for odour-free packaging applications. Archroma is well known for its innovations and sustainable solution systems aimed at helping packaging and paper manufacturers to optimise productivity and create value in their markets. The multifunctional Cartaseal® range offers barrier solutions that can be used to protect from grease, oils, water, and water vapour in both packaging and food packaging applications such as pizza boxes, sandwich wedges, fresh vegetables, fast food service, and general supermarket packaging. The latest addition to the range has been developed in line with the principles of “The Archroma Way to a sustainable world: safe, efficient, enhanced, it’s our nature”. The innovative coating is designed to form a continuous and defect-free film-like coating on the paper surface. The resulting barrier offers class-leading performance against the penetration of oils, fats, water, and vapour. The odour-free product is also ideally suited to food packaging applications, where the taste and smell of the packed food can be very sensitive to the environment and must be carefully preserved for the full enjoyment of the consumer. Thanks to its superior performance, Cartaseal® VWAF can be used as a more sustainable alternative to replace not only
Cartaseal® VWAF by Archroma
PFC-based coatings but also plastic in applications where resistance to water, oilS, fats and water vapor condensation is required. Developed with food packaging in mind, Cartaseal® VWAF is compliant with FDA and BfR requirements for food contact applications. It is also compliant with, eco-labels such as EU Flower, Nordic Swan, and several annexes of Blue Angel, and is of course REACH registered. Importantly, it offers increased potential for compostability, repulpability, and recycling compared to PFC and plastics since the coating will break down with the paper during the recycling process. Cartaseal® VWAF is at the core of the new PACK IT CLEAN system just launched by Archroma where it is combined with a primer solution for cases where a binder or pre-coat can also be used to further boost performance.
Image Source: Archroma
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“Consumers and regulators are increasingly attentive to how products are made, and rightfully so”, explains Mr. Andy Bell, Head of the Competence Center Chemicals at Archroma. “It is our responsibility as an industry to develop and convert to technologies that reduce our impact on the environment and on people’s health. That is exactly what we at Archroma do, with innovations like Cartaseal® VWAF. Because it’s our nature.”
P•R•O•D•U•C•T W•A•T•C•H
Cortec Introduces VCI Reinforced Paper for Packaging The Cortec CorShield VpCl-146 Reinforced Paper has a moisture barrier that acts as a barrier against moisture. Due to the characteristics, the packaging paper is easily adaptable to a number of packaging applications.
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ortec has introduced CorShield VpCl-146 Reinforced Paper, which ensures tear protection for heavy-duty, and puncture-prone packaging applications. The packaging paper has a moisture barrier, and a proprietary invisible corrosion inhibiting layer. As per the information shared by Cortec, one of the major challenges for metal manufacturers and finishers is corrosion during shipping and storage. Also, the Vapour phase Corrosion Inhibitors (VPI) in the coating vapourise and form protective corrosion inhibiting barrier on metal surfaces wrapped inside the paper. With respect to tear resistance, the CorShield VpCl-146 Reinforced Paper provides excellent tear resistance, especially when packaging oddly shaped metals or those with pointed or sharp edges. Furthermore, the CorShield VpCl-146 Reinforced Paper has a moisture barrier that safeguards it against moisture, making it suitable for protecting packages that are subjected to harsh and high humidity environments. The paper is also suitable for packaging parts that are covered with grease or processing oils that could leak through or break down the standard paper.
CorShield VpCl-146 Reinforced Paper. Image source: Cortec
Owing to the characteristics of the Reinforced Paper, it is easier to adapt to a number of packaging applications. This includes coils, wire reels, raw and machined forgings, castings, sheet metalwork, springs, fastenings, nails, and electrical and electronic components. At the beginning of the year, the company had introduced a new recyclable speciality film – EcoSonic VpCl Static Dissipative Stretch Film. The solution is for applications where static discharge could result in dangerous packaging conditions.
Amcor Introduces Compostable Paper Based Packaging At the beginning of this year, Amcor launched LifeSpan Performance Paper for the snacks and confectionary market.
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witzerland-headquartered Amcor plc, a global packaging company, has developed and introduced a compostable packaging solution for butter and margarine for Grupo Agroindustrial Numar S.A. in Costa Rica. The new packaging solution is made entirely from paper and is certified as home compostable by TUV.
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As per the information shared by Amcor Flexibles Latin America, which created the paper packaging, the paper packaging has the same shelf life and grease-proof properties as the previous paper and aluminium wrapping. The paper wrapper is claimed to be 38 percent lighter than the aluminium and paper lamination. The ASSET life cycle assessment informs
Growing with the Industry
An upcoming media company, Tulip 3P Media brings out publications for different B2B verticals. The activities of the company now embrace events and market research as well. Tulip is currently on its way to further expanding its publication portfolio through publications for other business verticals and a rich offering of other niche media services. Our Brands:Magazines
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that the production and manufacture of this all-paper packaging delivers an 81 percent lower carbon footprint along with decreased water consumption and lesser consumption of non-renewable energy. The team at Peru was dedicated to making sure that the solution is equally foldable as the previous packaging. The packaging company informs that the paper is certified by the European compostable governing body TUV as compostable both at home as well as in industrial settings. It was in 2018 that Amcor had committed to designing all of its packaging to be recycled, composted, or reused by 2025 – which made it to be the first global packaging company to do so. At the beginning of this year, Amcor launched LifeSpan Performance Paper for the snacks and confectionary market,
Image Source: Amcor
which reportedly has a paper fiber content of over 80 percent and offers high-barrier and grease-resistant properties while being recyclable.
JMC Introduces Carbon Steel Drying Cylinders The use of steel instead of cast iron allows a significant reduction in shell thickness which decreases thermal resistance and thus increases heat transfer.
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MC Paper Tech Pvt. Ltd. has launched the all-new era of steel drying cylinders. Truly, ‘Made in India’, the steel dryers provide numerous advantages to the paper companies in terms of energy-saving due to lower consumption, flexibility, investment costs, safety and weight. Since steel is a stronger material and has a modulus of elasticity that is considerably more than 2.1 times higher than cast iron, designing the pressure vessel safety codes allows for better design parameters on steel. The much higher allowable stresses for steel mean that the shell wall can be thinner, which gives the positive benefit of higher heat transfer rates. Lower shell root thickness for steel means the resulting heat flow is higher through the cylinder. This gives a higher evaporation rate which can flexibly either be used: to increase the production rate at constant energy input or, when the machine speed is kept constant, to reduce the drying energy. Yankee dryers can be metalised prior to increasing the surface hardness, life and water resistance. Metallisation eliminates the need for re-grinding of the shell wall base metal, which on cast iron can eventually result in de-rating. Metallisation is also a key reason that steel Yankees are far less prone to developing chatter problems. The drying cylinder of diameters 1220 mm, 1500 mm, 1800 mm, 2100 mm and face length up to 5.1 mtr are available with internal machining and grooving whereas Yankee cylinder of diameters 3048 mm, 3658 mm, 4267 mm, 4876 mm and
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Image Source: JMC Paper Tech
5486 mm and face length up to 5.1 mtr would be available without internal machining and grooving. Substantial field data available today from the company’s experience and client relations for steel dryer applications has led to technological and manufacturing process guiding principles. The use of steel instead of cast iron allows a significant reduction in shell thickness which decreases thermal resistance and thus increases heat transfer. Upon material procurement & manufacturing and completion, each fabricated dryer is thoroughly inspected with 100 percent ultrasonic and magnetic testing of all components. Phased array and 100 percent X-ray inspection are also performed on all structural welds. Dimensional and pressure tests are performed before the final approval of the cylinder.
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Abirami Pumps Develops Hydraulic Sealing System - An Advanced Sealing System for Pumps A hydraulic sealing system is an inbuilt seal with no requirement for special maintenance.
doesn’t allow the liquid entry to the stuffing box, when the pump starts the expeller creates positive pressure. However, when the pump is stopped to arrest the static leakage, a gland packing stuffing box is also provided. Mr. Guru Krishna, Chief Marketing Officer, Abirami Pumps
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birami Pumps has developed a hydraulic sealing system, an advanced sealing system for pumps and an alternative to the conventional gland packing system. Usually, a gland packing system is compiled to arrest the leakage, but, if damaged, it may have continuous leakage on the shaft sleeve. The hydraulic sealing system consists of an expeller mounted back to the impeller in the other direction which
During operation, 20 to 25 percent of the liquid enters the stuffing box area. An alternate sealing system is a mechanical seal that requires external sealing liquid and is very expensive. On the other hand, a hydraulic sealing system is an inbuilt seal with no requirement for special maintenance. Abirami Pumps has also launched APC 500/60 - a new model of double volute end suction back pull out type with energy-efficient process pump which can handle up to 7000m3 capacity with 50 mtrs head. It has also developed a special type of staggered vane impellers for low pulsation applications for the first time in the industry. The fan pumps can now be operated with a wide operating range without losing the minimum head requirements. “Pumps are one the most important energy-conserving equipment in any process industry. It also plays a major role in power consumption. We, at Abirami Pumps, are experts in power management on pumps. Updating the latest technology and innovating the new design is always there with us,” said Mr. Guru Krishna, Chief Marketing Officer, Abirami Pumps. “We are always working on reducing the power cost for pumps by improving the efficiency of the pump, and selecting the right pumps for the right system. We have more than 600 models of pumps for various duty parameters. More importantly, all our centrifugal pumps are coming under 7 rotor assemblies only, which helps the end-user to reduce the inventory cost,” he added.
116 | www.papermart.in / February-March, 2022
P•R•O•D•U•C•T W•A•T•C•H
Voith Starts EdgeSaver for Significant Savings in Valuable Virgin Fibers and Energy Consumption The EdgeSaver ensures a significant reduction of raw material costs along with a smaller carbon footprint.
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oith has introduced EdgeSaver, a new edge trim concept, to effectively enhance the range of products for stabilising the web edge in the headbox area. The innovative edge trim system trims the web edge in the stock jet exiting the headbox. Thus, it enables the paper manufacturers to save not only valuable raw materials such as virgin fibers but also reduce the energy consumption for paper production. The innovative design of the EdgeSaver blade brings a simple and energy-efficient solution for adjusting the web edge directly in the headbox jet. Since the fibers are discharged before the suspension reaches the wire, the fibers with a width more than the required paper web width are not lost in the couch pit. In addition, the web width can be customised as per specific customer requirements in the wet-end. Therefore, with EdgeSaver, there will be a significant reduction of raw material costs along with a smaller carbon footprint.
FORM IV Statement about ownership and other particulars about PAPER MART 1. Place of publication
: New Delhi
2. Periodicity of its publication
: Bi-monthly
3. Printer's Name Nationality Address
: Parveen Kumar Jain : Indian : F-14/22, Model Town-II, New Delhi-110009
4. Publisher's Name Nationality
: Parveen Kumar Jain : Indian
Address
: F-14/22, Model Town-II, New Delhi-110009
5. Editor's Name Nationality Address
: Parveen Kumar Jain : Indian : F-14/22, Model Town-II, New Delhi-110009 6. Names and addresses of individuals who own the newspaper and partners or shareholders holding More than one per cent of the total capital Address
Mr. Oliver Kern, Plant Manager at Papier- und Kartonfabrik Varel, says, “By using the Voith EdgeSaver, we consume less energy and therefore reduce our carbon footprint because the product allows high-quality fibers to be retained. This means, we not only produce more sustainably but also more cost-efficiently.” With EdgeSaver, the paper quality can also be significantly improved. Due to the specially manufactured side shield with a patented, adjustable S-shape, edge waves are minimised which also enhances the edge stability. The EdgeSaver can be fixed to the standard headboxes of all manufacturers and it can be easily installed on both sides of the web in just a few hours during the shutdown. In addition, changing the forming fabric also does not pose a challenge. The ingenious swivel device allows the forming fabric to be replaced seamlessly without having to restore the optimised settings on the EdgeSaver afterwards.
: Parveen Kumar Jain : F-14/22, Model Town-II, New Delhi-110009.
I, Parveen Kumar Jain hereby declare that the particulars given above are true to the best of my knowledge and belief.
Date: 01 March, 2022
Voith EdgeSaver concept. Image source: Voith
Signature of Publisher
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Mr. Andreas Jaeger, Plant Manager at MM Neuss GmbH, says, “The EdgeSaver enables us to variably adjust the paper web width without major rebuild measures. Even with changing production parameters, we are able to produce without restrictions, thus reducing breaks and production losses due to defects in the edge area.”
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ITC PSPD wins Pulp & Paper International Awards ITC PSPD won in the category of the ‘Internet of Things and Digitalization’, and has become the first Asian company to win the PPI award. April 4, 2022
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TC Ltd.’s Paperboards and Specialty Papers Division – ITCPSPD has won the Pulp & Paper International (PPI) Awards, in the category of ‘Internet of Things and Digitalization’ at a ceremony held in Lisbon, Portugal in March 2022.
The PPI Awards, organised annually by Fastmarkets RISI, are dedicated to recognising and honouring the achievements of companies, mills, and individuals in the pulp and paper industry. ITC PSPD has become the first Asian company to bag this global award. The award recognises the achievement of leveraging existing systems for value creation. Industry 4.0 interventions deployed by the company include advances in data capture and management at every node of the supply chain, working with advanced IoT technologies to enhance efficiency and reliability in operations, production, and costs, and driving a new paradigm of quality. According to the statement of ITC PSPD, “The award is recognition of a rapid transition to a future-tech enterprise, a milestone in a journey of digital transformation.”
Image Source: ITC Ltd.
The PPI Awards are organised to recognise and celebrate leadership, innovation, and strategic accomplishments in the forest products industry.
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: dsengineers_raj@yahoo.com / dspl@ymail.com
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www.papermart.in / February-March, 2022 | 119
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Ashoka Kraft Industry orders Shoe Press from Parason Machinery The shoe press will provide immense advantages in terms of improving the dryness in addition to reducing the overall steam consumption up to 15-20 percent. April 7, 2022
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shoka Kraft Industry LLP has placed an order for a Shoe Press from Parason Machinery (India) Pvt. Ltd. The company is coming up with a 400 TPD kraft paper manufacturing plant in Assam. The Greenfield plant near Guwahati will be producing high BF and high RCT kraft paper and is well-equipped to produce quality papers. As a part of the plan, Ashoka Paper wanted to buy Shoe Press for their paper machine. They have evaluated all the suppliers and have chosen Parason Machinery for the supplies of the complete Shoe Press. “Ashoka Papers is coming up with a 400 TPD plant in Assam and we have to be ahead of time in terms of the quality of paper we produce. We have decided to place an order from Parason because of their proven track record in the market and their engineering capability,” said Mr. Mohit Gupta, Director – Ashoka Kraft Industry LLP. “Parason has been working in the Paper Industry for the last 45 years. The customers have always shown trust and interest in our newly developed products. In continuation to
Parason Machinery receives order from Ashoka Kraft Industry
Shoe Press section by Parason Machinery.
this, we have been awarded a Shoe Press order from Ashoka Kraft Industries. We are completely ready with the entire Shoe Press Technology and are very well-equipped to deliver indigenously manufactured Shoe Press. We are committed to working for the dream of Aatmanirbhar Bharat. Parason Shoe Press will give an immense advantage to the paper mills. It will improve dryness after the press section and hence will reduce overall steam consumption up to 1520 percent. Apart from this, there is improvement in the formation of the paper – RCT value would go up and machine runnability would be improved to a great extent. This would result in higher productivity and lower costs of production. This is very important especially when steam and energy costs are on the rise. Shoe Press will be a great investment opportunity as it will have the fastest ROI for our customers. This is our second order of the Shoe Press,” confirmed Mr. Kishor Desarda, Director, Parason Machinery (India) Pvt. Ltd. “Tycon automation would be providing an entire automation solution for the Shoe Press”, added Mr. Rohit Tickoo, Director, Tycon Automation Pvt. Ltd.
Purbanchal Paper Mill to Set Up a 150 TPD Plant in Assam Assam-based Purbanchal Paper Mill would have Paper Machinery supplied by DS Engineers & Pulp Mill By Parason Machinery, Rolls, Boiler, and ETP from Ashoka Rolls, Cheema Boilers Ltd., and Chemical Kraft, respectively. April 8, 2022
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urbanchal Paper Mill LLP is going to come up with a kraft paper manufacturing plant with an installed capacity of 150 TPD. Located near the upcoming Multi Modal Logistics Park, Purbanchal Paper Mill would be manufacturing kraft paper from 80 to 200 GSM in 16 to 24 BF. It would have a 4.1 m deckle machine with 3850 mm as a finished paper deckle.
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Image Source: Purbanchal Paper Mill
N•E•W•S The company’s proximity to the international borders of Bhutan and Bangladesh will apparently provide the mill an opportunity to export to these two neighbouring countries. Purbanchal Paper Mill LLP would have rolls, Multi Fuel Dual Furnace boiler, and ETP from Ashoka Rolls, Cheema Boilers Ltd., and Chemical Kraft respectively. Automation, power distribution, and electrification solutions will be supplied by ABB & Tycon Automation Pvt. Ltd. The complete paper mill machinery & section of the pulp mill would be supplied by DS Engineering. The mill would reportedly be getting the pulping solutions supplied by the Parason Group. Promoted by Mr. Ajay Agarwal, Founder & MD, Nipco Group (India) and M.P. Agarwalla Group, Assam, and also Including Mr. Shyam Patwari, Mr. Aditya Agarwal, and Mr. Bikash Agarwal as Whole-time Directors, Purbanchal Paper Mill LLP is an Assam-based manufacturer of paper. The total cost of the project is approximately INR 80 crores. The company has already acquired extra land for its phase 2 expansion plan.
Purbanchal Paper Mill site.
In phase 2, the company intends to expand its capacity from 150 TPD to 225 TPD. It will also set up an integrated captive 4 MW power project.
Spento Papers (India) LLP Commences Production of Duplex Board & White Top Kraft Liner Morbi, Gujarat-based Spento Papers mill, which is equipped with advanced production lines, has expanded its production with the aim to fulfill the requirements of coated duplex paperboards. March 5, 2022
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pento Papers (India) LLP has successfully started the production of duplex boards and white top kraft liner. With its headquarter and paper mill in Morbi, Gujarat, Spento Papers is currently one of the leading manufacturers and exporters of coated white back and grey back duplex boards. The organisation operates four-wire part adaptable paper machines capacity of 108000 TPA to produce a wide portfolio of products. The paperboards are lightweight and have impressive attributes of high stiffness, rigidity, and robust nature. They have a slick surface, high smoothness, and are extensively printable, which makes further use of the papers versatile with production aiding features. The coated white back duplex board features eight-level composition and uniform coating. Made from recycled paper pulp, it is eco-friendly and a food-grade product.
Image Source: Spento Papers
Spento Papers mill, Morbi (Gujarat)
Meanwhile, the coated grey back duplex boards are created with a white exterior and grey interior layer. The exteriors are calendared on one side, providing a white and smooth surface suited for offset printing and a coated grey texture inside. Coated with bright pulp pigments, the duplex board provides a glossy appearance and the feature also facilitates better-quality printability. Equipped with imported and most advanced manufacturing machines, which are in line with international quality and standards, the Gujarat-based mill aims to fulfill the requirements and prerequisites of the consumers with the best solutions in the industry. www.papermart.in / February-March, 2022 | 121
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Line O Matic Celebrates its Silver Jubilee The Company has installed more than 3000 machines in over 75 countries in the past two and a half decades. April 13, 2022
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hile Line O Matic Graphic Industries' official entrance into the paper and packaging industry was marked 25 years ago, one can trace back their expertise to over 50 years ago! The company’s journey initially began under the banner of the GGI (Gunvantray Graphic Industries) brand. Later in 1997, the company got registered under a new name, Line O Matic, by Mr. Uday Patel. The aim was to become an industry leader in producing top-notch exercise notebook machinery. And to achieve this feat, they leveraged technological advancements to provide superior products and high-quality services. Attaining 100 percent customer satisfaction – has been driving the company to always outdo everyone's expectations. As the years progressed, so did their journey from old-age machinery to new-age technology. The automatic machines helped adjust to the versatility of paper requirements for the paper converting and packaging industry. The constant efforts to achieve perfection have brought the company this far! Today, Line O Matic has earned its name in the market as a professional company and a pioneer in manufacturing stateof-the-art machinery for paper stationery, paper converting, and packaging industry. What enables them to be a market
leader and drive their growth is their understanding, expertise, and focus on the customers’ needs by adopting a sustainable approach. Mr. Uday Patel, Founder & Owner, Line O Matic Graphic Industries, says, “Our biggest motivating factor is our customers and vendors. Their unwavering support has driven us to keep working harder and coming up with innovative solutions that don't just match their requirements but supersede their expectations as well. Everyone's contribution is the key to our success, and therefore, we earnestly acknowledge the part each of you has played to make our ordinary journey, an extraordinary one.” In the last two and a half decades, the company has garnered ample accolades while achieving numerous milestones. Having installed over 3000 machines in over 75 countries, the company strives to constantly push boundaries and set brilliant benchmarks along the journey to success.
Pap-tech expands its Portfolio to Serve Pulp & Paper Mills Better The company has been in the manufacturing, exporting and importing equipment since 1997. April 10, 2022
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ap-tech Engineers & Associates has diversified its product range by providing complete paper and pulp machines to the pulp and paper industry. Besides fulfilling the A to Z machinery requirements of the mills, the company also delivers maintenance and commissioning services to its customers. The company has been in the manufacturing, exporting and importing of physical testing equipment, bursting strength tester, and pulp testing equipment since 1997. It has now expanded its portfolio by introducing new products and services. “Our mission is to set up paper mills from 100 TPD to 600 TPD at economic prices with the best quality in terms of production and quality. Customer satisfaction is our motto,” says Mr. V.K. Agarwal, CEO, Pap-tech Engineers & Associates. The company also provides refurbished paper machines from 50 TPD to 600 TPD. “We have a team of engineers in paper engineering, mechanical engineering and electronics engineering. Pap-tech has already provided a complete tissue
122 | www.papermart.in / February-March, 2022
Image Source: Pap-tech
machine of 30 TPD tissue and 45 TPD poster paper which has been working for the last five years. We are also providing a complete kraft paper machine in Alwar, Rajasthan for 120 TPD in 3200 mm width and a writing and printing paper machine of 100 TPD in Nepal for 3400 mm width. Some projects for the coated duplex board and packaging kraft papers are in the discussion stage,” adds Mr. Agarwal. In the paper machine section, the company provides hydraulic headbox, pressurised headbox, press section, dryers, suction rolls, coaters, rewinders, soft nip and hard nip calenders and synchro fly cutters. It provides centricleaners and pressure screen baskets in all sizes for stock preparation. The firm has a good client base.
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ITC PSPD all set for Paperex 2022 At the Paperex 2022, ITC PSPD will showcase its range of ‘Filo’ Series which they have recently introduced as a substitution to single-use plastics. April 25, 2022
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s the pandemic blues fade away and the Pulp & Paper industry witnesses renewed excitement, the largest Paper & Paperboard manufacturer in India – ITC Ltd. – Paperboards and Speciality Papers Division (ITC PSPD) – is gearing up to be part of the biggest industry event – Paperex 2022. The 15th edition of Paperex, to be held from 10-13 May at India Expo Centre- Greater Noida, is expected to attract major
industry players, key executives, professionals and customers from the Pulp, Paper and allied industries. ITC PSPD will be setting up an exclusive ‘ITC Lounge’ at the event, where visitors will get to experience their exciting range of paper and paperboards catering to several industries like Pharma, F&B, FMCG, Publishing etc. The highlight would be their range of plastic substitution products under the ‘Filo’ series – FiloBev, FiloPack and FiloServe – which they have recently launched as alternatives to single-use plastic disposables. These products are fully recyclable in standard recycling systems and have quickly caught the eyes of customers looking for sustainable packaging solutions. The ‘ITC lounge’ will also feature private meeting rooms to facilitate oneon-one discussions with interested customers.
Image source: ITC PSPD
Scan Machineries Bags Significant Orders from Paper Mills The company has recently commissioned a 200 TPD kraft machine for Kanha Paper Mills Pvt. Ltd. at Siliguri in West Bengal. March 15, 2022
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can Machineries Pvt. Ltd. has bagged important projects from paper mills. The company has recently commissioned a 200 TPD kraft machine for Kanha Paper Mills Pvt. Ltd. at Siliguri in West Bengal. It is also rebuilding Sapphire Paper Mill Pvt. Ltd. for a 125 TPD Writing & Printing Machine stock preparation from Voith. Apart from these, Scan Machineries is also supplying a 350 TPD kraft machine for Suvarna Durga Group which is in the advanced stage. It has dispatched air-pressurised headbox to Kraft paper machine
Waraq, Saudi Arabia, and a hydraulic headbox with European technology to Emami Paper Mills Ltd. One of the leading paper machine manufacturers Scan Machineries installs and optimises complete paper machines and production lines for the production of kraft paper, writing and printing paper, tissue paper, specialty paper, packaging, and board grades.
(From left to right) Mr. Vinod Nargunam, Director and Mr. Christy Selvan, Director, Scan Machineries Pvt. Ltd.
It also provides full turnkey paper mill solutions. Founded in 1989, the motto of the company has always been ‘Passion for Paper’ and it stands true to it by expanding its product lines and conducting research & development in accordance with European standards. www.papermart.in / February-March, 2022 | 123
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Evernew Paper Commences Production on Single Wire Kraft Machine purchased from JMC Paper Tech The machine has a deckle size of 4100 mm, with a running speed of 300 MPM (maximum operating speed of 250 MPM). March 9, 2022
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vernew Paper LLP has started the commercial production of paper on a single wire kraft machine purchased from JMC Paper Tech Pvt. Ltd. The company has set up a 120 TPD kraft paper plant at Morbi, Gujarat. With a deckle size of 4100 mm, the machine is designed to run at a speed of 300 MPM (with a maximum operating speed of 250 MPM).
The single wire paper machine has proposed scope for top wire in the future. JMC Paper Tech has supplied the complete section of the paper machine beside the partial pulp mill section. In addition, the company has also supplied the finishing equipment. The raw material used includes – OCC, NDLKC, and KCC.
Image Source: JMC Paper Tech
Before entering the paper industry, the management team of Evernew Paper LLP was in the ceramics & laminates industry as M/s Symphony Ceramics, M/s Om Laminates & M/s Parimal Trading Co.
European Union removes ban on Waste Paper Exports to India The decision by the EU to lift the ban on waste paper exports to India will provide a helping hand to mills facing a raw material shortage. April 5, 2022
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he European Union (EU) has withdrawn its ban on exports of waste paper to India, effective from April 1, 2022, as published in news reports. This move will provide relief to the Indian paper industry which is undergoing a shortage of waste paper. Waste paper is the primary raw material for the waste paper/ recycled paper-based paper mills. Apparently, the EU banned the exports of these cuttings in November last year. However, it was later turned out to be a clerical error. Now, thankfully, the issue has been finally resolved as the EU released a notification on March 31 stating its approval of the export of waste or recovered paper. Meanwhile, the order came into effect on April 1. The move of allowing the waste paper exports will resolve the raw material-related issues of the Indian paper industry which is facing a shortage of waste paper cuttings, especially after the advent of the COVID-19. Also, the consumption of paper such as writing & printing and newspapers decreased sharply as the world was hit by the pandemic. Moreover, China had imposed a ban on the import of waste paper among a few other items. The shortage of waste paper cuttings had more than quadrupled their prices from earlier.
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Waste Paper and Cardboard Bales for Recycling
Besides, increasing freight costs also further increased the prices of waste papers. As the imported waste paper will be made available to the pulp and paper manufacturers, the raw material shortage will be resolved to a certain extent. Nevertheless, to reduce the import dependence of the domestic paper industry for waste paper, the collection efficiency of waste paper should be improved in the country.
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Orchid Group Continues to Register Robust Growth The sales growth has been remarkable, particularly during 2020 and 2021 despite the COVID-19 pandemic, wherein revenue witnessed a year-on-year growth of 30 percent. April 20, 2022
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rchid Group, known for producing one of the finest and most consistent qualities of coated paper boards, has made a name for its quality and excellent print results. The company’s sales growth has been remarkable, particularly during 2020 and 2021 despite the COVID-19 pandemic, wherein the revenue witnessed a year-on-year growth of 30 percent. Apparently, the group has set the vision for 2023 and is working to substantially add to the production capacity and enhance the quality and product value. Starting with a small capacity of 15000 TPA in 2007, Orchid Group has grown to the present capacity of 210000 TPA with ‘customer first’ as its core policy. The group produces coated paper board (duplex paper board), kraft liner, and absorbent kraft in three paper machines in addition to the HPL sheets, which has effectively led to a better product mix and diverse portfolio. The paper machine at the facility is equipped with DCS and QCS which ensures consistency in the quality of the products.
Image Source: Orchid Group
The finishing house is equipped with eight Synchro Fly sheeting machines that ensure trim-free and burr-free boards. Known for producing smell-free paper, and its environmental conservation and CSR activities, the Orchid group has always been proactive in sustainable growth and has been a pioneer in water management. A major requirement of the paper production needs is met by the rainwater harvesting method. The group has discontinued the use of fossil fuels and is now reliant on sustainable alternative fuels for the boilers. Further, it is 100 percent reliant on renewable energy for all the paper production and is expanding the energy production and growing that into a new business vertical.
Ambica Paper Machineries to Expand its Global Presence In 2009, the company got its first international order which led it to extend its portfolio. It now aims to become a pioneer manufacturer and exporter of paper mill machineries. April 24, 2022
Mr. Jayantibhai Panchal, Chairman, Ambica Paper Machineries
Mr. Nirav Panchal, Managing Director, Ambica Paper Machineries
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mbica Paper Machineries, one of the trusted manufac turers and exporters of pulp and paper mill machineries, is eyeing global expansion. The company got its first interna tional order in 2009 which led it to extend its portfolio. It now aims to become a pioneer manufacturer and exporter of paper mill machineries. Talking about the expansion plans of the company, Mr. Jayantibhai Panchal, Chairman, Ambica Paper Machiner-
ies, says, “Today, our serving is not only up to India, but we have stepped into the global market as well. We would like to share the credit of this significant journey with investors, dedicated staff, management, and Image Source: Ambica Paper Machineries our all beloved clients and customers. At this stage of our journey, I am confident to share that with our consistent commitment, hard work, innovation, ambition, and support, we are going to achieve greater heights in a concise time.” Located in Gujarat, Ambica Paper Machineries was incorporated in 1987, starting with manufacturing pulp cleaning machines. “For the last 4 decades, Ambica Paper Machineries has witnessed consistent growth, and success and faced many challenges by serving domestic as well as international markets with the best paper and pulp machineries. We feel proud to be the pioneer manufacturer and exporter of paper machineries not only in India but also in the international market,” adds Mr. Nirav Panchal, Managing Director, Ambica Paper Machineries. www.papermart.in / February-March, 2022 | 125
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APRIL Group Invests in Paperboard Packaging Mill to Support Indonesia’s Economic Development The new production facility is aligned with the Indonesian Government’s plans to develop a green economy. The additional supply for production capacity will come entirely from APRIL Group’s supply chain. March 29, 2022
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eading sustainable fiber and product producer Asia Pacific Resources International Limited (APRIL Group) has strengthened its commitment to supporting the growth of the green economy in Indonesia. The company is set to expand its product portfolio in the downstream sector by investing IDR33.4 trillion (USD 1.9 billion) in a sustainable paperboard production facility.
The construction of the new facility - which will be located at APRIL’s operations in Pangkalan Kerinci, in Riau province, Sumatra - is one of the largest manufacturing investments in Sumatra in the last decade. The investment is expected to support Indonesia’s continued economic development and recovery following the COVID-19 pandemic through the diversification of sustainable downstream fiber products with added value. When completed, the paperboard packaging facility will be capable of producing 1.2 million TPA of folding boxboard that is fully recyclable and biodegradable. This growth is to meet the demand for more environmentally friendly packaging products in the domestic and international markets. APRIL launched its APRIL2030 targets in November 2020 to deliver a positive impact on the climate, nature, and people, while growing its business sustainably over the next decade. The development comes as a global focus on reducing the use of plastics, polyester and other fossil fuel-based materials gathers pace. Demand for recyclable and biodegradable options for everything from packaging to fashion is being driven by consumer preference via expanding e-retail purchases in highgrowth markets such as China, Indonesia, India, and Vietnam.
Image Source: APRIL Group
The global paperboard packaging market is expected to grow by 3 percent this year, also driven by increased food production linked to population growth and lifestyle changes such as the preference for individual packaging and food deliveries. APRIL Group’s fiber supply comes from 100 percent renewable plantation sources. Additional supply for expanded production capacity will come entirely from its existing supply chain. The company has posted a 40 percent increase in fiber yield over the past five years from its existing plantations while also committing USD 1 per tonne of plantation fiber produced towards landscape conservation. The company has targeted a 50 percent gain in fiber plantation productivity by 2030. The investment in downstream diversification and value-added products is also in compliance with APRIL Group’s Sustainable Forest Management Policy 2.0 which includes no deforestation. It will directly contribute to the achievement of the company’s APRIL2030 commitments, including net-zero emissions from land use, zero net loss of conservation areas, positive biodiversity gains, and zero extreme poverty in its communities.
Bangladesh-Based City Group Ventures into Tissue Market, Orders Tissue Line from Toscotec The AHEAD 2.2 tissue line has a design speed of 2,200 m/min and a production capacity of over 40,000 TPA. City Group has ordered an extensive service package including YES-CONNECT-VISION Augmented Reality remote assistance system. March 2, 2022
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angladesh-based City Group has ordered an AHEAD 2.2 tissue line on a turnkey basis from Toscotec. With this expansion, the Bangladeshi consumer goods manufacturer
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sets out to enter the tissue market. The new tissue mill will be erected in Hoshendi Economic Zone near Dhaka. The production is projected to start in 2023.
N•E•W•S The AHEAD 2.2 machine has a design speed of 2,200 m/min and a production capacity of over 40,000 TPA. It is designed for superior drying efficiency through the combination of the latest generation design of both TT NextPress shoe press and TT SYD Steel Yankee Dryer, as well as TT Hood with multistage energy recovery. The turnkey supply encompasses the complete stock preparation and fiber recovery systems, the patented TT SAF® Short Approach Flow with double dilution, the full electrification plant, Toscotec's proprietary control system, and all associated auxiliary systems. Toscotec will also deliver the new OPTIMA 2200 slitter rewinder designed to preserve the bulk and softness of the mother reel. Md. Imran Uddin, Director of Planning & Business Development at City Group, says, “When we set out to enter the tissue market, we did a careful evaluation of machinery manufacturers at global level looking for a supplier of turnkey projects who could also provide all the assistance we needed to succeed. We decided on Toscotec because they offered the highest guarantee of advanced technology and wide experience in giving full-on support to newcomers in tissue.” City Group ordered an extensive service package including detailed engineering, erection supervision, training commission-
City Group Paper Mill
ing, start-up assistance, and YES-CONNECT-VISION Augmented Reality remote assistance system. Mr. Gabriele Martinelli, Toscotec Sales Manager, says, “It is always exciting for us to take on a project of a company entering the tissue market. This is the second turnkey project in two years in Southeast Asia. We are happy to share our experience with City Group through technical meetings, visits to our workshops and to paper mills operating Toscotec’s tissue lines. We knew it was important for them to look at key components such as TT SYD and TT NextPress, and then see them in operation.”
BillerudKorsnäs and Viken Skog to explore possibilities for jointly producing BCTMP pulp The aim of the feasibility study is to establish a production line for BCTMP pulp at the Follum mill which has the adequate infrastructure and accessibility to wood supply. March 4, 2022
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illerudKorsnäs and the Norwegian forest owner group Viken Skog are forming a joint venture to explore the possibilities of working together to establish the production of bleached chemi-thermomechanical pulp (BCTMP) at Viken Skog's Follum mill in Hønefoss, Norway.
Firstly, the two companies – BillerudKorsnäs and Viken Skog are planning to initiate a feasibility study about future pulp production at Follum. This will be completed during the first half of 2023. The intention is to establish a state-of-the-art production line for BCTMP pulp at the Follum mill with a capacity assumption of up to 200 Kilo Tonnes Per Annum (KTPA). The Follum mill already has much of the infrastructure needed to establish such a production line and is located in an area with competitive and sustainable wood supply and good transports to BillerudKorsnäs' board mills. Mr. Christoph Michalski, President, and CEO of BillerudKorsnäs, comments, "This initiative forms part of BillerudKorsnäs' strategy for sustainable and profitable growth and supports our
Image Source: Viken Skog
ambition to grow in paperboard. To cover the increasing need for BCTMP for our growing board operations, we want to explore the possibilities of producing this pulp quality in Follum together with Viken Skog. As part of this partnership, the intention is also to enter into a long-term wood supply agreement with Viken Skog. We initially see good prospects for creating an efficient supply chain and competitive access www.papermart.in / February-March, 2022 | 127
N•E•W•S to the raw materials needed to produce the packaging materials of the future." If the project will proceed after the feasibility study is completed, the investment for BillerudKorsnäs is estimated to be in the range of 600-800 MNOK. Olav Breivik, Chairman of the Board in Viken Skog, comments, "With BillerudKorsnäs, we have found a solid partner
who, like us, wants to implement an efficient supply chain and explore sustainable product opportunities provided by the forest raw material. The existing infrastructure at Follum provides a promising basis for establishing pulp production with a relatively low investment need. We will in the feasibility study also explore the possibilities for producing biogas, and later also solutions for carbon capture at Follum."
Stora Enso Planning to Divest Four of its European Paper Mills The four Stora Enso production sites are subject to divestment either in one or a series of transactions. The Langerbrugge site in Belgium, which produces recycled newsprint and recycled supercalendered magazine grades, will be retained in the Group. March 30, 2022
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inland-headquartered Stora Enso has initiated a sales process as it is intending to undertake a possible divestment of four paper mills. Keeping in view the strategy of Stora Enso, the divestment plans are in tandem with the longterm growth plans for its segments including – renewable products in packaging, building solutions, and biomaterials innovations. The paper production sites which are intended for divestment are – Anjala in Finland, Hylte and Nymölla in Sweden, and Maxau in Germany. The assets are high-quality sites for pulp and paper production with strong infrastructure, and skilled and experienced staff.
In the Anjala Mill, printing paper from mechanical pulp — both coated and uncoated book paper, magazine paper, and improved newsprint grades are manufactured. The Hylte Mill, one of the largest newsprint mills in the world, produces high-quality newsprint, biocomposites, and formed fiber products. The Nymölla Mill is a producer of pulp and woodfree uncoated paper. Maxau Mill produces supercalendered paper primarily from recovered paper.
Stora Enso paper mill in Hylte, Sweden
All the four Stora Enso production sites are subject to divestment in one or a series of transactions. The Finnish company has not committed any deadline for the conclusion of the divestment process. The planned sales process would not have any immediate effect on the paper production operations. The Langerbrugge site in Belgium, one of the most efficient recycled newsprint and recycled supercalendered magazine paper mills in the world, will be retained within the Group.
Valmet Continues to Strengthen its Stable Business by Acquiring Coldwater Seals Coldwater is the global leader for suction roll seals and plastic dewatering elements and a leading provider of consumables and services to the pulp and paper industry. March 2, 2022
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almet has acquired North America-based Coldwater Seals, Inc., a global provider of consumables and services to the pulp and paper industry. Coldwater has manufacturing
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facilities in the United States and Sweden. The value of the acquisition will not be disclosed.
N•E•W•S The Georgia, US-headquartered Company manufactures and supplies paper process parts, including – suction roll seal strips, ceramics, plastics, doctoring products, and other specialty products. The company is the global market leader for suction roll seals and plastic dewatering elements. With global operations, the North American company has Technical Service Representatives in more than 70 countries. In the last twelve months, the company had net sales of approximately EUR 15 million. The acquired operations employ about 60 people, who are located in Atlanta and Appleton in the U.S. and Kil in Sweden. Aki Niemi, Business Line President, Services at Valmet, says, “We are continuously strengthening our stable business, meaning Services and Automation. This acquisition supports the strategy to expand our consumables offering. I warmly welcome the
Coldwater has manufacturing operations in USA and Sweden.
new skilled professionals to become part of the Valmet team and into our strong, global Services organization.” “I am convinced that the future of Coldwater is in good hands with Valmet,” adds Mr. David Withers, Owner, and CEO of Coldwater Seals Inc.
Mondi Accelerates Sustainable Growth Plans with EUR 280 million Investment in Corrugated Packaging Mondi is planning to infuse EUR 185 million across the corrugated solutions plant network and EUR 95 million at Mondi Swiecie containerboard mill to meet the rising demand for sustainable packaging. March 24, 2022
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ondi Group is investing EUR 280 million in corrugated packaging operations across four countries. This includes around EUR 185 million across its central and eastern European Corrugated Solutions plant network and EUR 95 million at Świecie’s containerboard mill in Poland. These investments are a part of the packaging firm’s EUR 1 billion in expansionary capital investment projects in sustainable packaging. Mr. Markus Gärtner, CEO of Corrugated Packaging at Mondi, says, “Ongoing investment in our Corrugated Packaging business supports our MAP2030 commitments around circular-driven packaging and paper solutions, created by empowered people taking action on climate.” The upgrade of Mondi Świecie’s containerboard mill, comprising an extensive rebuild of PM2 and PM5, a new anaerobic treatment plant including an integrated cooling system, and upgrades to the pulp mill, the recycled fiber line, and the ener-
Image Source: Mondi
gy recovery system. These improvements will allow the mill to meet growing customer demand for heavy-duty applications, enhance product quality, and bolster its environmental performance by decreasing water consumption and wastewater emissions. The plant at Mondi Warsaw more than doubled in size and capacity, and receiving new machinery and automation, including a corrugator of an industry-leading 3.35 m in width. Investments in operations in Turkey focused on the newly-acquired Mondi Olmuksan plants, with Gebze specialising in eCommerce packaging production, and Bursa reinforcing its heavy-duty output with the addition of sheet production. The Izmir site will be transformed by a modernisation and expansion programme. Mondi Tire Kutsan Karaman will also get a new high-quality printing case maker. About the expansion, Mr. Armand Schoonbrood, COO of Corrugated Solutions at Mondi, says “The investments in state-ofthe-art machinery for our Mondi Olmuksan plants expand our offering to customers in the region in line with our ambition to become a leading player in the structurally attractive Turkish market.” The expansion of the Kuopio semi-chemical fluting mill also remains on track. The EUR 125 million investments announced last year will increase the facility’s capacity by around 55,000 TPA. The project includes an upgrade of the wood yard, fiber line, evaporation plant, and paper machine, with a start-up planned for the fourth quarter of 2023. www.papermart.in / February-March, 2022 | 129
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BillerudKorsnäs completes the Acquisition of Verso The company is strengthening its strategy to achieve profitability and sustainable growth, and boosting its presence in North America. April 11, 2022
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weden-based BillerudKorsnäs has completed the acquisition of Verso Corporation for about USD 825 million in a cash deal. Ohio, USA-based Verso Corporation is a leading producer of coated papers, including – coated groundwood, coated freesheet, supercalendered, and specialty products.
The acquisition of Verso represents the strengthening of BillerudKorsnäs’ strategy to achieve profitability and sustainable growth and is in line with its goal to boost its growth in North America. Due to this acquisition, BillerudKorsnäs will now be one of the largest providers of virgin paper and packaging materials. The Swedish company is committed to continuing to serve the US-based manufacturer’s customers in all the segments. It will also work on its plans to transition several of Verso’s assets into paperboard machines while maintaining the latter’s position as a quality and cost leader in speciality & coated paper. Speaking about the acquisition, Mr. Christoph Michalski, President & CEO, BillerudKorsnäs, remarks, “Our combined assets and expertise in high-quality virgin fiber paper and board packaging materials create an excellent platform for sustainable and profitable growth. Integration work starts immediately, and we look forward to working together, sharing knowledge, initiating preparations for the conversion project, and realising a successful development.” Mr. Rob Kreizenbeck, Verso’s SVP of Operations, will now hold the position of President, North America in BillerudKorsnäs' Executive Management Team, effective April 1,
The combined company operates 10 production facilities in Sweden, U.S., and Finland. Image source: Privata Affärer.
2022. Going forward, BillerudKorsnäs intends to shorten its company name and brand to – Billerud. "We are excited to join forces with BillerudKorsnäs and become a larger, stronger organisation. Together, we are building a company that is passionately committed to strong safety culture, sustainability, superior quality, and delivering value to our customers,” says Mr. Rob Kreizenbeck. The combined company operates 10 production facilities in regions including – Sweden, U.S., and Finland with around 5,800 employees in more than 13 countries and serving customers in over 100 countries.
Stora Enso Exploring Expansion Opportunities in Renewable Consumer Packaging Boards Post-conversion, the planned production capacity of the board line at the Stora Enso Oulu site would be 750,000 TPA of FBB, coated unbleached kraft, and liner grades. March 9, 2022
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tora Enso will carry out a feasibility study to assess the possibility of converting a paper machine at its Oulu site (Finland) into a high-volume consumer board production line. Once the feasibility study is completed, the Finnish provider of renewable solutions would decide about the investment
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by the end of 2022 while the production is expected to start in 2025. The strategy of investing in sustainable packaging is one of the key focus areas for the company to further develop its
N•E•W•S market share in the segment in which it already holds a leading global position. The planned investment in Oulu is aimed at producing high-quality and low carbon-footprint packaging for frozen and chilled food and beverages, and non-food applications like pharmaceuticals and cosmetics. The feasibility study will also assess how the conversion could contribute to Stora Enso’s Science Based Targets initiative (SBTi) regarding carbon emissions. Hannu Kasurinen, Executive Vice President, Packaging Materials division, says, “This investment would respond to the strong customer demand to replace plastic in packaging. During the study, we will evaluate the profitability of the possible conversion and how to optimise current production synergies to create a modern mega-site at Oulu.” Once the board production line is fully ramped- Image Source: Stora Enso up, the top-line sales impact of the conversion would be EUR chemi-thermomechanical pulp (BCTMP) plant, the biomass 800 million. Meanwhile, the capital expenditure is estimated boiler, and the effluent treatment plant. to be EUR 900–1,000 million during 2023–2026. The investThe planned annual capacity of the converted machine ment would be made in - the conversion of the former paper would be 750,000 TPA of folding boxboard (FBB), coated unmachine, the sheeting facility, wood handling, the bleached bleached kraft (CUK), and liner grades.
Mayr-Melnhof Holz Acquires Bergkvist Siljan After the acquisition, Mayr-Melnhof Holz will grow its lumber production capacity by about 50 percent to more than 2.7 million m3 of sawn timber annually. February 21, 2022
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ustria-headquartered Mayr-Melnhof Holz has got the necessary approval from the competition authorities regarding the acquisition of the Swedish sawmill Group Bergkvist Siljan. The deal is expected to finalise during the first quarter of 2022. The new sites in Insjön, Mora, and Blyberg, which are all in central Sweden, perfectly complement the existing sawmill sites in Leoben in Austria, Paskov in the Czech Republic, and Efimovskij in Russia. Further, this also moves Mayr-Melnhof Holz, with around 5 million m3 of log processing capacity, up to be the third-largest European sawmill. With the acquisition, the group now expects for the first time in its 170-year long history, a turnover to surpass EUR 1 billion in the 2022 financial year. Bergkvist Siljan has an annual production capacity of about 850,000 m3 of spruce and pine sawn timber. The company has three sawmill sites and one of the largest container terminals in Sweden. Speaking about the acquisition, Richard Stralz, CEO of the Mayr-Melnhof Holz Holding AG, remarks, “The Mayr-Melnhof
Image Source: Bergkvist Siljan
Holz Group and Bergkvist Siljan make a perfect fit. Both have comparable roots, both are family businesses with a long tradition exceeding 100 years and both are committed to sustainability. We are looking forward to rewarding cooperation and the mutual exchange of experiences.” Post-acquisition, Mayr-Melnhof Holz, being one of the leading companies in the European sawmilling and engineered wood products industry, will grow its lumber production capacity by about 50 percent to more than 2.7 million m3 of sawn timber annually. www.papermart.in / February-March, 2022 | 131
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Paper Province makes LignoCity accessible from all over the world With the aim to make the Lignin Plant LignoCity widely accessible, Paper Province brings the option of a digital tour of the facility. February 24, 2022
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aper Province has brought a digital version of the platform LignoCity, which is the test and development facility for the forest raw material lignin. With the digitisation of the platform, the geographical boundaries are no longer a constraint as it is now possible to tour the plant from all over the world. Lignin is the natural and fossil-free alternative to fossil-based solutions. It can be regarded as a natural adhesive owing to its binding properties for fibers and strength. Lignin is currently an underutilised material with huge scope and potential for further growth in industries. LignoCity brings an open test and development environment. Fundamentally, it is a physical place welcoming anyone – either researchers, businesses, or students, for ideas and products related to lignin. Situated next to the paper and pulp mill Nordic Paper, Kristinehamn, Sweden, Lignocity is at the heart of the forest industry where expertise, raw materials, and contact networks can be easily accessed. Ms. Sandra Sundbäck, CEO of Paper Province, comments, "Paper Province is one of several actors that actively work to support the test facility and the use of lignin."
Image Source: Paper Province
In a bid to make LignoCity accessible and have a wider reach, there is the option of a digital tour of the facility. It means that it does not matter where you are located because one can visit the pilot plant via digital mode. Ms. Maria Ölmhult, Project Manager, RISE Bioeconomy and LignoCity, says, “Being able to offer this feels very good, not least in the situation everyone is in now, where digital tools of communication are used to the maximum. We can meet in digital meetings and now also show our facility without anyone having to travel here. This way, we will hopefully attract more people.”
Jiangxi Five Star Paper orders high-capacity P-RC APMP line for its Pulp Mill from ANDRITZ Jiangxi Five Star Paper, a part of Quzhou Wuzhou Special Paper Co. Ltd., will install the P-RC APMP (Pre-Conditioning Refiner Chemical Alkaline Peroxide Mechanical Pulp) technology which ensures optimum pulp quality at the lowest energy consumption. April 12, 2022
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hina-based Jiangxi Five Star Paper Co., Ltd. has ordered a high-capacity, chemi-thermomechanical pulping system from ANDRITZ. The startup of the line is scheduled for 2023. The international technology group will provide its P-RC APMP (Pre-Conditioning Refiner Chemical Alkaline Peroxide Mechanical Pulp) technology which ensures optimum pulp quality at the lowest energy consumption. The pulp will be utilised in the manufacturing of Folding Boxboard (FBB) with eucalyptus wood chips as the raw material. The new fiberline, with the capacity of 1,500 admt/d, will be the largest system worldwide based on a single-line concept with only one HC refiner.
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ANDRITZ TX68 refiner. Image source: ANDRITZ
N•E•W•S ANDRITZ will provide the main equipment, including – chip washing to the storage tower. The scope of order also includes the basic engineering and the supervision of mechanical installation, commissioning, and startup.
Specialising in the production of specialty paper, Jiangxi Five Star Paper has been a part of Quzhou Wuzhou Special Paper Co. Ltd. which is one of China’s largest food wrapping paper producers, since 2015.
J&J Green Paper teams up with CERAX to expand Eco-Friendly Packaging The production of fully compostable and eco-friendly food packaging products, as a result of the synergy between J&J Green Paper and Cerax, will be in conformation with the EU Directive. March 30, 2022
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s the new European Directive with respect to single-use plastics came into play, many companies are looking for ways to conform to the laws pertaining to eco-friendly food packaging. Keeping this in view, J&J Green Paper, Inc., a Miami, USA-based manufacturer of sustainable paper products, and CERAX PTY Ltd., a South African maker of specialty waxes, have formed a partnership. The production and supply of green paper products are expected to expand as an outcome of their association. Commenting on the partnership, Mr. Scott Segal, CEO of J&J, remarks, “Having greater access to this material to make and coat paper for food, beverage, and other consumer products directly helps the environment by reducing plastic waste and greenhouse gasses.” Within the agreement, J&J Green’s patented JANUS, that is, a moisture-proof coating will be rolled out at the facility of Cerax at Jet Park, Johannesburg, South Africa. At present, the plant has the capacity to produce 24,000 MTPA of specialty waxes with the potential for further expansion. JANUS is an all-natural and moisture-proof solution that is used in the manufacturing of paper and paper packaging. The solution is designed to provide paper producers with an alternative to current fossil fuel-based moisture-proof solutions that
J&J Green’s JANUS will be rolled out at the facility of Cerax in South Africa.
creates toxic greenhouse gasses. The bio-based coated paper is the world’s most eco-friendly paper owing to its properties of being organic, recyclable, compostable, and repulpable. With the JANUS coating, rigorous industrial paper quality standards can be met at a cost lesser than polyethylene glycol (PEG) coated papers along with also abiding with the EU Directive 2019/904, requiring the elimination of single-use plastics. Mr. Stuart Prior, Managing Director of Cerax, says, “For almost 35 years, Cerax has been producing high-quality industrial waxes on the African continent.” He further adds that this move is not the first one for Cerax into alternate eco-friendly waxes, but it is still significant. Moreover, the licence to produce J&J’s proprietary and breakthrough paper coating enhances Cerax’s product line as well as it stands perfectly with global trends.
Valmet launches Beyond Circularity Project to Boost Green Transition The Finnish company plans to invest EUR 40 million into the project during the upcoming four-year period. March 28, 2022
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almet Oyj will launch a new R&D and innovation project called Beyond Circularity, which improves the readiness to support the green transition in Valmet’s customer industries based on the company’s technology vision 2030.
The project is aimed at further strengthening the R&D work in order to develop process technologies, automation, and services for utilising renewable materials and recycled waste, and side streams. Furthermore, the project also enables fur-
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N•E•W•S ther improving the energy efficiency of its process technologies and the use of fossil-free energy in the pulp and paper industry customers’ production processes. The Finnish company plans to invest EUR 40 million into the project during the upcoming four-year period to execute its technology vision and climate program and generate growth. The project is partly funded by Business Finland and is part of the “Veturi” initiative, where international companies are invited to solve some of society’s most pressing challenges, through increased research, development and innovation investments in Finland. Mr. Janne Pynnönen, Vice President of Research and Development, Valmet, says, “A new green transition ecosystem is to be built as part of this project, which is expected to create value and growth for the participants, expand competencies to new areas and encourage the best national and international
Image Source: Valmet
partners in the field to join. The core of the ecosystem is Valmet’s unique triangle approach of technology, automation, and services enriched by the interdisciplinary know-how of the partners.”
Norske Skog Bruck in Austria orders Automation and QCS from Valmet The paper machine conversion project is aimed at transitioning the PM3 from newsprint to recycled containerboard production with a capacity of 210,000 TPA. March 28, 2022
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orske Skog Bruck mill in Austria has ordered a Valmet DNA Automation System, and Valmet IQ Quality Control System (QCS) for its paper machine PM3. The Austrian paper mill had selected the Valmet automation systems based on good references in technology, service support, and low ownership costs. The installation is scheduled to start in the fourth quarter of 2022. Speaking about the project, Mr. Christian Trieb, Maintenance Manager Electrical and Automation, Norske Skog Bruck GmbH, says, “We selected Valmet’s automation’s solution due to our long and reliable partnership with the company as our mill wide automation supplier.” Mr. Markus Kohl, Service Manager Austria & CEE, Automation business line, Valmet, says “We are very proud to be selected as the automation solution supplier for Norske Skog Bruck’s project. It will ensure them an easier, more efficient, and secure operation and maintenance through a common user interface and engineering environment.” The delivery is a part of Norske Skog's major paper machine conversion project which has the target of transitioning the PM3 from newsprint to recycled containerboard production with the capacity of 210,000 TPA. The scope of delivery consists of the system design, engineering, manufacturing, factory acceptance test, and instal-
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Image Source: Valmet
lation of the Valmet DNA Automation System. The distributed control system (DCS) will cover the PM3 including OCC, and water treatment plant extension. All controls are in one platform that allows users easy access to the data and efficient collaboration. The Valmet IQ QCS will be supplied for PM3 including scanners, related measurements, Valmet IQ Moisturizer, multivariable MD (Machine Direction), and CD (Cross Direction) controls. This will furnish accurate and stable sheet quality in demanding machine conditions, improving paper quality and efficiency. It also includes Valmet IQ Dilution profilers and Valmet IQ Web Monitoring System.
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IPMA - Indian Pulp & Paper Industry Seeks Priority Allocation of Coal The shortage of coal is directly impacting the captive power plants of the pulp and paper manufacturers. April 22, 2022
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he Indian pulp and paper industry has been undergoing an overwhelming crisis due to the unavailability of coal. This is severely impacting the operations of the pulp, paper, and paperboard manufacturers in the country. The production at a number of paper mills has been critically affected while a few other paper mills are on the verge of shutting down. Sharing the urgent requirement of the coal for paper mills, IPMA (Indian Paper Manufacturers Association) asserted, “Paper Industry being a continuous process industry and energy cost accounting for a significant part of the total production cost in paper mills, the industry has invested a huge amount of money in setting up captive power plants.” The coal crisis is impacting the captive power plants of the pulp and paper mills due to the unreliable and shortage of coal supply. Thus, the association for the paper industry has been urging the government for the priority allocation of coal as the Indian Railways also takes up a substantial share in addition to thermal power plants. In the face of this coal scarcity, the industry fears the closure of mills if the supply of coal does not get reinstated, affecting all the segments of the paper industry.
IPMA urged the government for the priority allocation of coal as the looming crisis of coal shortage is intensifying.
IPMA also said, “Pulp & Paper Industry has requested for priority allocation of coal and railway rakes for captive power plants of the Industry as paper and paperboard touches all aspects of life and its production is vital for education, packaging, and several other sectors of the economy.”
Gloris Paper Begins Commercial Production on its Single Wire Absorbent Kraft Machine JMC Paper Tech supplied the complete section of the paper machine and the total cost of the project was around INR 45 crores. February 18, 2022
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loris Paper LLP has started the commercial production of paper on a single wire absorbent kraft machine with a dandy roll purchased from JMC Paper Tech Pvt. Ltd. The company set up a 200 TPD absorbent kraft paper plant at Halvad in the Morbi district of Gujarat, last year. With a deckle size of 4150 mm, the machine is designed to run at a speed of 300 MPM (with a maximum operating speed of 275 MPM). The dandy roll mounted on the wire part helps to flatten the top surface as well as improve the finish. JMC Paper Tech has supplied the complete section of the paper machine beside the partial pulp mill section. The total cost of the project was around INR 45 crores.
Single Wire Absorbent Kraft Machine
Apparently, the company has also supplied the finishing equipment. The raw material used includes–OCC, NDLKC, and KCC. www.papermart.in / February-March, 2022 | 135
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Shawano Specialty Papers orders TT SYD Steel Yankee Dryer from Toscotec The recent order by Shawano Specialty Papers further strengthens the position of Toscotec in the USA as the leading supplier of Steel Yankee dryers. March 31, 2022
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SA-based Shawano Specialty Papers, a subdivision of Little Rapids Corporation, has ordered a TT SYD Steel Yankee Dryer from Toscotec. The manufacturer of a range of paper products has made the order for the dryer for the paper mill in Shawano, Wisconsin, USA. The dryer will be installed on PM3 and the installation is scheduled to take place in the third quarter of 2022. The new TT SYD will be put in place of the existing cast-iron dryer at the Shawano paper mill. Toscotec’s new-generation steel yankee dryer will bring a number of advantages to the mill including significant production increase, and thermal energy savings. It will also lessen the operating costs of the tissue machine and assure higher safety than the conventional steel dryers. Speaking on the association with Toscotec, Mr. Jeff Wolf, Engineering Manager, Shawano Specialty Papers, said, “The decision to choose Toscotec for this replacement is based on our trust in their first-rate technology and Toscotec’s years of experience with SYDs. We have two main focuses: first to provide high-quality solutions for our customers and second to continuously reduce our energy consumption and overall environmental impact utilising state-of-the-art technology.” Toscotec is the globally leading developer and supplier of Steel Yankee dryers and there are more than 240 TT SYDs that have already been sold worldwide. The recent order further strengthens its position in the US market as the key supplier of Steel Yankee dryers, occupying the largest market share.
Image Source: Toscotec
Commenting on the several benefits of the TT SYD, Mr. Michael Drage, President, Toscotec North America, Inc., says, “We expect Shawano Specialty Papers to start reaping the benefits of our latest-generation design Steel Yankee dryer right after start-up. Drying efficiency is key in the tissue industry. A high-tech, energy-efficient component such as TT SYD will give them an important competitive advantage to further expand their business in North America.”
Hamburger Containerboard Collaborates with Voith for OnPerformance.Lab In view of increasing the efficiency of the line and optimising the quality of production, Hamburger Containerboard had been associated with Voith’s OnPerformance.Lab for more than a year now. With this successful collaboration, the Austrian mill has decided to rely on OPL as a long-term partner. March 31, 2022
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ustria-headquartered Hamburger Containerboard has collaborated with Voith for the OnPerformance.Lab (OPL). With assistance from Voith’s OnPerformance.Lab’s experts, the containerboard mill has achieved 35 percent faster grade
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changes, optimised length profile, and more stable processes on the paper machine PM1 at the Spremberg site. Hamburger Containerboard, a member of the Prinzhorn Group, has the manufacturing capability to produce around
N•E•W•S 340,000 TPA of paper on the PM1. The line produces white uncoated and coated papers and gypsum board with basis weights ranging between 120-180 GSM. With the aim to enhance the efficiency of the line and optimise the quality of production, the Austrian corrugated paper mill has been associated with OnPerformance.Lab experts from for just over a year. The process of the remote optimisation started with accumulating the data of all relevant processes and machine from PM1. The collected data was used by Voith to develop possible solutions for increasing the efficiency of the plant. Later on, the OPL experts discussed the issues occurring on the machine, refined the models, adjusted controller settings, and suggested the pertinent program changes in the customer control system. Mr. David Wötzel, Engineer Automation QCS, Hamburger Rieger GmbH in Spremberg, elaborates, “Thanks to their comprehensive expertise and holistic approach, the OPL experts defined individual and reliable recommendations that stabilised our process and ultimately led to a significantly shorter grade change time. The cooperation was simple, flexible, and smooth throughout the entire period.” The measures that have been implemented are already having a positive economic impact and higher production is now achievable, owing to the OPL system.
Hamburger containerboard associated with OnPerformance.Lab experts from Voith.
Mr. Wötzel further adds, “You can simply tell that OnPerformance.Lab is staffed by experts who know how complex the papermaking process is and which solution approaches are individually suitable.” As an outcome of this successful collaboration and positive experience, Hamburger Containerboard will continue to depend on the expertise of the OnPerformance.Lab as a longterm partner.
Burgo Group, Avezzano goes for a Rebuild of PM2 from ANDRITZ The rebuilt press section will enable the Burgo Group to achieve a reduction in steam and specific energy consumption, while also reducing the carbon footprint. March 31, 2022
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urgo Group has ordered a rebuild of the press section of its paper machine PM2 at the Avezzano mill, Italy to ANDRITZ. The startup of the PM2, which is a test liner/white top liner machine, is scheduled to take place in the first quarter of 2023. The new press section will have a design speed of 1,200 m/ min and a width of 5.32 m at the pope reel.
The rebuild is targeted at significantly enhancing the dryness content after the press along with saving energy and improving other paper properties. The rebuilt press section will enable the Burgo Group to achieve a reduction in steam and specific energy consumption, while also resulting in the reduction of the carbon footprint. The scope of the order includes – a new PrimePress X shoe press for the 4th nip, with a line load of 1,450 kN/m. With this type of shoe press, the highest dry content levels are possible compared to the market standards. Moreover, the runnability of the machine will be improved. In the last few years, ANDRITZ has delivered various equipment items as well as services to Burgo. For instance, the
ANDRITZ has delivered various equipment items as well as services to Burgo in the past few years.
conversion of the PM2 from graphic paper to containerboard grades also included the delivery of a new stock preparation line and a new top wire. With this rebuild, the Burgo Group is strengthening its ambition to constantly reduce energy consumption – one of the goals defined in the group’s sustainability strategy. www.papermart.in / February-March, 2022 | 137
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Stora Enso Expands its Formed Fiber Production Capacity in Europe Post-investment, the annual formed fiber capacity of the Hylte site in Sweden will be around 115 million units, making Stora Enso one of the leading suppliers of formed fiber in Europe. February 22, 2022
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tora Enso will invest EUR 8 million (~USD 9.07 million) to double its production capacity of formed fiber in Europe. With the new production line in Hylte, Sweden, the Finlandbased Packaging and Biomaterials Company will be able to meet the increasing demand for formed fiber. With the investment, Stora Enso’s position is further cemented as a leading provider of renewable materials that replace fossilbased ones. The formed fiber products of the company are utilised in food packaging products like bowls, trays, and lids. Their technology is also utilised in producing fiber bottles. Following the investment, the annual formed fiber capacity of the Hylte site will be scaled up from 50 million units to around 115 million units, making Stora Enso one of the leading suppliers of formed fiber in Europe. Formed fiber is renewable, recyclable, and biodegradable, and they are being used to replace plastics in a number of applications. PureFiber™ is a range of formed fiber products with no per- and polyfluoroalkyl substances (PFAS) and has about 75 percent lower carbon footprint as against alternative packaging materials like plastic or bagasse.
The formed fiber products are used in food packaging products like bowls, trays, and lids.
Mr. Sohrab Kazemahvazi, Senior Vice President, Head of Formed Fiber at Stora Enso, says, “There is a high demand in the market for eco-friendly, circular packaging solutions that replace plastic and other fossil-based materials. Our formed fiber offering can help brand owners meet their sustainability targets while responding to consumers’ demands for a cleaner future.”
PT Mega Surya Eratama orders key components from A.Celli Paper The Indonesia-based paper mill has selected A.Celli for the end line of their new packaging paper production line to be installed in the Mojokerto paper mill. February 22, 2022
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T Mega Surya Eratama and A.Celli have signed an agreement for the full-optional end line solutions for the packaging paper production line in Mojokerto paper mill, Indonesia. The PM2 will produce an average of 1,360 TPD of testliner and medium corrugated having a width of 6,700 mm and the basis weight in the range of 90 to 180 GSM. With the planned expansion, the PM2 will be the most advanced and productive line in the country for these products. The scope of the contract includes – a PMT-designed pope reel capable of processing rolls with a diameter of 4400 mm and a design speed of 1350 m/min, and the acclaimed E-WIND® P100 with the full-optional configuration.
Image Source: A.Celli Paper
Moreover, the paper rewinder, which will process reels at a design speed of 2600 m/min, will be equipped with – an in-line unwinder and four in-line reel parking stations, an automatic
The considerable diameter and width of the jumbo rolls to be processed make this production line a unique project. The startup of the production line is scheduled to take place in 2023.
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spool parking, a web-in slittomatic system for the automatic positioning of the slitting units, and tail and core gluing systems.
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WestRock plans to develop a new Corrugated Box Production Facility in Washington The upcoming state-of-the-art manufacturing facility will serve all industry segments in the Pacific Northwest market. February 18, 2022
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S-based paper packaging company WestRock will build a new corrugated box plant in Longview, Washington. The sustainable packaging provider has decided to build the plant in view of the increasing market demand for eco-friendly packaging solutions in the Pacific Northwest region. Speaking about the production expansion, Mr. David B. Sewell, Chief Executive Officer, WestRock, comments, “WestRock’s corrugated packaging business in the Pacific Northwest continues to perform well, with strong relationships with customers in attractive growth markets.” The new corrugated plant will cater to every industry segment. Upon completion of the facility, the plant will replace the company’s current corrugated operations in Longview. The corrugated plant, which would be co-positioned with the Longview paper mill, will further expand the integration of the mill’s containerboard production.
Representative Image: Corrugated Boxes
Sewell further added that their new corrugated packaging plant will enable its team in this region to cater to their customers in a better way. The upcoming state-of-the-art manufacturing facility will also provide new capabilities and efficiencies for the customers in the region.
Schumacher Packaging buys major stake in Kartonfabrik Kaierde The acquisition of Kaierde is a part of Schumacher Packaging EUR 700 million investment program through 2025. The investment is planned for the development of the company’s plants as well as futuristic technologies. February 18, 2022
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ermany-based Schumacher Packaging Group has bought a majority stake in Kartonfabrik Kaierde, a board producer with a manufacturing facility in Delligsen, Germany. Presently, the board production plant has a capacity of 25,000 TPA of greyboard and unbleached board. The acquisition will increase the company’s solid board production capacity by 50 percent from 50,000 TPA to 75,000 TPA, which the company views as an important step to ensure raw material supply. The acquisition of Kaierde is a part of Schumacher’s EUR 700 million investment programme through 2025. The investment is planned for the development of Schumacher’s plants as well as in futuristic technologies. Explaining the aim behind the acquisition, Mr. Hendrik Schumacher, CEO, Schumacher Packaging Group, says, “The Kaierde board mill offers us an outstanding opportunity to expand our work in the solid board sector. When demand increases or resource shortages lead to production bottlenecks, this takeover will enable us to provide our customers with reliable fu-
Image Source: Schumacher Packaging
ture prospects, guaranteeing supply reliability in the future.” Post-acquisition, the Schumacher Packaging Group will have a presence in 18 sites across Europe including its existing board mill in Schwarzenberg, as well as a solid board processing facility in Hauenstein, in the Palatine region. www.papermart.in / February-March, 2022 | 139
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Arctic Paper Kostrzyn orders a Fiber Furnish Analyzer from Valmet Valmet Fiber Furnish Analyzer provides paper, paperboard, and tissue paper makers with fast and precise online updates of key fiber and papermaking furnish properties. April 6, 2022
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rctic Paper Kostrzyn S.A. has ordered a Valmet Fiber Furnish Analyzer (Valmet MAP Q) with services for its Kostrzyn plant located in the western part of Poland. The value of the deal has not been disclosed. The order is scheduled to be delivered in the second quarter of 2022. Owing to systematic investments, the manufacturer of offset and graphic papers has been able to improve the quality of paper production and further enhance the efficiency in manufacturing.
Arctic Paper Kostrzyn S.A.
About the association with Arctic Paper, Mr. Markku Merra, Sales Manager, Automation Business Line, Valmet, remarks, “We are very pleased to cooperate with Arctic Paper, as they are strongly aware on the environmental issues. Our solution will help them to minimise the environmental impact and use raw materials efficiently while improving the quality of their end-products.”
Providing paper, paperboard, and tissue paper makers with fast and precise online updates of key fiber and papermaking furnish properties, Valmet MAP Q is the state-of-the-art online fiber analysis system. It is an outcome of continuous advancements made over the past forty years. One of its major benefits is the increased energy efficiency and refiner segment life while maintaining the highest pulp quality.
Domtar Ashdown Mill A62 Paper Machine is Now Fully Operational The previously idle machine – A62 Paper Machine at the Ashdown Mill, is set to resume operations in view of the increasing customer demands. It will enable Domtar to maintain its position in the uncoated freesheet paper. April 13, 2022
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he Ashdown Mill of Domtar Corporation in Arkansas has resumed the operation of the A62 paper machine. Restarting the non-operative paper machine, as well as a sheeter to convert the rolls into cartons of copy paper, will enable Domtar to maintain the leadership position in the North American uncoated freesheet paper market segment. The production of the A62 paper machine was halted in April 2020 — in view of the lull seen in the customer demand with the advent of the COVID-19 pandemic. Mr. Rob Melton, Senior Vice President, Pulp and Paper Commercial, Domtar Corporation, says, “With offices, businesses, and schools closed in a large part of our markets, we had to take the appropriate steps to optimize our operations and match our capacity to our reduced demand.” However, as the economy is reviving from the impacts of COVID-19, the decision was made to resume the operations of A62, which means adding again the paper production capabilities to meet the growing customers’ demands.
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The A62 Paper Machine has been made operational in view of the rising demand for paper and paper products.
Nevertheless, restarting a machine such as A62 would require a time span of a few months to steadily build the machine up to its current 24/7 run schedule. “With customer demand for paper on the rise, we knew we had to act quickly to restart the machine to ensure we could continue to meet our customers’ needs,” says Mr. Bill Edwards, Senior Vice President, Pulp and Paper Operations, Domtar Corporation.
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Voith and Trützschler Nonwovens to Supply Second Carded/Pulp system at EcoWipes’ Nowy Dwor Site, Poland EcoWipes has ordered a new carded/pulp (CP) line from Voith and Trützschler Nonwovens for the Nowy Dwor site in Poland. The new plant will produce sustainable and cost-effective hygiene wipes. April 22, 2022
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he Polish nonwovens manufacturer EcoWipes has commissioned Voith and Trützschler Nonwovens with the delivery of a second carded/pulp (CP) system at the Nowy Dwor site in Poland. The first CP line, which was also supplied by Voith and Trützschler Nonwovens, has been a great success thanks to the increasing demand for environmentally friendly hygiene wipes on the international markets. With the help of CP technology, a cost-effective, wet-laid pulp layer can be combined with a carded nonwoven layer made of cellulose fibers. The environmentally friendly CP nonwovens are 100 percent degradable, cost-effective to produce, and meet all market requirements. “We have a very good partnership with Voith. Therefore, when the full-line supplier, together with Trützschler Nonwovens, launched CP technology on an industrial scale a few years ago, we took the risk – and it paid off, even faster than we thought,” says Mr. Gabriel Kermiche, CEO of EcoWipes. “Our hygiene wipes are in great demand in Poland, in Europe, and even overseas. Based on the leading technologies and with our own process innovations, we have developed our patented Tricell nonwoven. Due to the high pulp content, we can also significantly reduce production costs.” The CP technology from Voith and Trützschler stands for the highest performance and product quality. Customer-oriented BlueLine stock preparation and forming technologies from the full-line supplier Voith are used. The compact FloatLip former will ensure efficient and sustainable production of the hygiene wipes.
EcoWipes Site
The cylinder mould former from Voith has proven itself in many board machines worldwide, as Mr. Oliver Crasser, Sales Manager at Voith Paper confirms: “Our FloatLip former is very space-saving, energy-efficient and maintenance-friendly. With the help of the cylinder mould former, homogeneous distribution of the stock suspension is possible. In this way, very uniform surface profiles can be achieved.” On top of the pulp layer, the Trützschler NCT high-speed card places a light layer of viscose or lyocell fibers. This configuration enables precise layering and efficient dewatering. Without the use of chemicals, the AquaJet by Trützschler combines both layers into an inseparable composite nonwoven with the highest functionality. A multi-drum dryer and a powerful winder complete the production line, which enables production speeds of up to 300 m/min. To optimize the production processes, EcoWipes also relies on digitalization and automation solutions as well as services, which Voith and Trützschler Nonwovens supply for both the existing and the new line.
Swiss Aseptic Packaging Major SIG to Invest in a Packaging Plant in India SIG India started its domestic presence with a local office in Gurugram in November 2017. With the new plant, the company’s operations will be further enhanced as it plans to serve more dairy and FMCG brands. April 18, 2022
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witzerland-headquartered SIG, a leading systems and solutions provider of aseptic packaging, is planning an investment in a new packaging plant in India.
The strategic investment is directed toward enhancing the company’s operations in the country. As published in news reports – India is one of the fastest-growing markets for SIG. www.papermart.in / February-March, 2022 | 141
N•E•W•S The company had shared a statement without sharing much detail about the specifics of the investment. About the investment, Mr. Samuel Sigrist, Global CEO of SIG Group, remarks, “After opening our second plant in China and starting construction of a plant in Mexico for the North American market, India is our first priority for the next investment in a new packaging plant. The decision-making process is still ongoing, but we are very confident that we will be able to start building a plant in India in the near future.” The time to develop the new SIG packaging plant will be about 12 to 18 months, Mr. Sigrist further added. According to the statement released by the company, Mr. Sigrist will visit India next week along with a team that includes the newly-appointed president and GM, Asia Pacific South, Ms. Angela Lu, and Mr. Samuel Dambreville, Director Cluster Asia Pacific South. “This is Sigrist’s first trip to India as Global CEO, and the aim of this visit is to meet customers and industry experts to further understand and discuss the future of the Indian market,” the company said. SIG India established its local office in Gurugram in November 2017. Beginning its business in the country with two custom-
ers - ITC and Coca Cola India, the customer base of the packaging provider now consists of several leading FMCG brands including Amul, Dabur, Varun Beverages (PepsiCo bottler), Haldirams, Milky Mist, and Godrej Creamline. “Today, with a base of 17 high-speed filling machines across the country and a full-fledged experienced local team, SIG is looking to further accelerate its growth trajectory in India,” it added. Furthermore, SIG has also been developing Image Source: SIG India-centric solutions to expand its business, serving more packaged dairy, and juice brands.
Paper Mills in Delhi-NCR to switch to PNG/Biomass from October 1 onwards The paper mill owners express that ensuring the availability of biomass and PNG gas in accordance with the demand of the mills in the region will pose a challenge. March 11, 2022
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ccording to the media reports —all paper mills in Delhi-NCR must transition to PNG or biomass fuel by September 30 this year. The notice was issued by Air Quality Management Commission Member Arvind Nautiyal on February 4 to the principal secretaries of Uttar Pradesh, Haryana, Rajasthan, and Delhi. The paper mill owners express that ensuring the availability of biomass and PNG gas in accordance with the demand will be quite challenging. Moreover, the maintenance-related costs, to safeguard the biomass fuel from environmental factors like rain and water, will increase for the mill owners.
Mr. Pankaj Aggarwal, President of Paper Manufacturers Association (UP) and owner of Bindal Duplex, said, “The PNG gas is not available here and it is also three times more expensive. If the paper mills use biomass, then about 5 thousand tonnes of husk, bagasse, wood, etc. will be required every day. However, the major challenge is that only 30 percent of the required consumption can be fulfilled in these mills using biomass.”
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Representative Image: Paper Mill
Meanwhile, the government is making provisions to give incentives to farmers for adopting best practices to utilise paddy straw in an eco-friendly manner to solve the issue of stubble burning. The paddy straw can be used in the boilers of paper mills.
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