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For more Notes, Presentations, Project Reports visit a2zmba.blogspot.com hrmba.blogspot.com mbafin.blogspot.com Overview of Paper Industry The Indian paper industry has been historically divided on a three dimensional matrix identified by size, grades manufactured and raw material utilized. Generally, tariff rates have protected smaller units utilizing “unconventional” raw material. Over the years, the growth of various segments, investments levels in specific segments, technolog techn ological ical chan changes, ges, industry industry fragmentat fragmentation ion and intensity intensity of competitio competition n have been significantly influenced by the Government tariff policy. The present Excise duty on Paper is 12 %. The Government of India from time to time has given some benefits to small industries in order to protect them i.e. the first 3500 tones produced by a mill is chargeable only @ 8 % and thereafter it i t is @ 12 %. The three main grades of paper manufactured in India are :1. Newsprint 2. Writing and printing. 3. Industrial Variety ( Craft paper and Duplex Board ) Over 550 players currently populate the industry and the estimated capacity is about 7.00 7.0 0 millio million n Me Metric tric Tones Pe Perr Ann Annum um (MTPA) (MTPA).. Fragm Fragment entati ation on is severe severe in the “industrial” (packaging) grades, which rely on “unconventional” raw material such as waste paper and partly agro residues. This division generally comprises of units with an average size of about 10000 MTPA and contributes to 45% of the output of paper and paper boards in the country. Although the other divisions in the Indian paper industry are also fragmented by international standards, the degree of fragmentation is less severe. “Newsprint” till about 1995, was the sole preserve of large public sector units and was well protected by high import tariff barriers. Nevertheless, imports contributed to about 50% of the domestic consumption. Since then, new domestic capacity with private investment has been allowed to be created. This
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growth has relied namely on De-inked waste paper as a source of raw material. Curr Curren ently tly impo import rt du duty ty on ne news wspri print nt is ab abou outt 5% an and d do dome mest stic ic manu manufa fact ctur ure e of newsprint is exempted from excise duty. This tariff structure for newsprint has seen Indian newsprint price closely mapping international prices. Imports still constitute abou ab outt 30 30% % of co cons nsum umpt ptio ion n an and d ne news wspr print int co cont ntri ribu bute tes s ab abou outt 10 10% % of the the tota totall produc production tion of pap paper er and pap paperb erboar oards. ds. The The number number of pla player yers s in the ne newsp wsprin rintt segment is relatively limited and manufacturing capacities are larger than in the packaging grades segment. Historically, the bulk of the output of “Cultural” grades – comprising of writing, printing, office stationery paper and specialty paper has been the preserve of “large” producers, who use forest based raw material in integrated pulping facilities augmented by imported pulp. This segment has been consistently taxed at higher rates due to its size and use of “conventional” forest based raw material. Investment in plant has also been higher. With relatively smaller number of players and high import tariff protection, prices of end products, generally perceived to be higher quality, have been high. Import tariff levels, although much lower now, still continues a significant barrier to impo imports rts.. The The high high inve invest stme ment nt leve levels ls requ require ired d an and d limi limite ted d “con “conve vent ntio iona nal” l” fib fiber er resources are the major deterrents to growth in this segment for both existing players as well well as new ent entran rants. ts. “Lower “Lower end cultur cultural al grade grades” s” manufa manufactu ctured red by smalle smaller r players using unconventional raw materials in low investment, low tech plants cater to consumers in the price sensitive sub segment of this market. This sub segment depends significantly on the tariff differential based on size and raw material for its viability. The Indian Paper industry is going through substantial changes. Global demand for paper is expected to grow by about 4% p.a. over the next 5 years. The domestic demand is expected to grow at about 8% which will result in increase of demand by 30 Lakh tones approximately over the next 5 years. It is expected that customs duty on import of paper will decrease from the current level to the level of 10% over a period of time due to WTO compulsions. The import of raw material for paper including pulp, waste paper and news print is likely to increase by at least 15% to 20% in 2005-06 to keep up with growing demand
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for paper in the domestic market. Despite to the constraints like over crowded market and limitation in procuring the desired quality of waste paper, there are indicators of a revival in the Indian Paper Industry. In the current year, selling price has marginally increased and enabled the industry to partially offset the rise in cost of inputs, fuel & labour. The paper industry has an important social role to play for the country. Use of paper is considered as an index of cultural growth. Key social objectives of the Government like eradicating illiteracy, making primary education compulsory etc. are very much relate related d to the pap paper er ind indust ustry. ry. The pa paper per ind indust ustry ry is also also con contri tribut buting ing toward towards s fu fulf lfill illme ment nt of va vari riou ous s requ requir irem emen ents ts of the the indu indust stry ry as a whol whole e like like info inform rmat atio ion n dissemination, publicity etc. which in turn stimulate industrial growth of the country. The paper industry has, thus, a catalytic role to play not only for the overall growth of the industry but also for the living standards of the people. The new millennium is going to be the millennium of the knowledge. So demand for paper would go on increasing in times to come. Because of paper industry’s strategic role for the society and also for overall industrial growth, it is necessary that the paper industry performs well.
FUTURE PROSPECTS The globalisation of Indian economy has lead to a healthy growth of 6 to 7% industry and an d th that at is grow growth th ha happ ppen enin ing g in all all the the se sect ctor ors. s. Mo More reov over er the the Pe Perr Capi Capita ta consumption of paper in India is going up with the advent of packaging in the food industry. Due to environmental concerns, the use of plastics is likely to be banned by the Government of India within a short span of time. Hence within 2 to 3 years we will be witnessing an explosive growth of packaging in India mainly in food, textile and export segments. The exposure to foreign packaging technology and the need to satisfy the export cust cu stom omers ers ha has s led led to a dras drasti tic c ch chan ange ge in the the indu indust stria riall pa pack ckin ing g se sect ctor or.. The The
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corrugators have started using high BF, high GSM paper instead of the regular grades and shifting from 7 ply and 9 ply boxes to 5 ply and 3 ply boxes. The above change has resulted in more aesthetic and cost effective packing solutions. There is a very good potential market developing for such grades of paper in India. The market of high quality Kraft paper is now catered only by few manufactures from western and northern parts of the country. With the above changes in the industry it would be in the best interest of our company to put up a Kraft paper plant of 100 MT per day producing high B.F., higher GSM paper and exploit the emerging market situations better. The company envisages the following advantages by going for such a plant as follows: l) Most of the existing paper mills in South India operate with single wire machine, which can produce up to 24 BF only, whereas the new plant intended to be set up by SSPML is a twin wire machine which can produce high quality Kraft paper of 24 BF to 40 BF which is sold in the market at a premium. l By making high end paper in sout so uth h In Indi dia a th the e co comp mpan any y stan stands ds to ga gain in a lot lot in term terms s of logi logist stic ics s co cost sts s when when compar compared ed to the competiti competition. on. l SJPML SJPML got the advantag advantage e of cost cost ben benefi efitt while while importing raw materials and exporting finished product. l The possibility of exporting substantial quantity of the production to near by countries like, Sri Lanka and eastern African countries is also bright. This may also be substantiated from the fact that paper exports have risen at a CAGR of 14 % pa from 105000 tonnes in the year 2000 to 179000 tons in the year 2004. As a strategic measure to expand the international operations of the company, the company has already started a new business division – International Business Unit to handle the international marketing operations of the Company. 2) The company intends to manufacture the paper by using Twin Wire Technology and an d also also plan plans s to inco incorpo rpora rate te all all lat lates estt eq equi uipm pmen ents ts to ha have ve a co cost st effe effect ctiv ive e production. The twin wire technology employs two wires drawing pulp stock from two separate head boxes. The arrangement is in such a way that the wet webs come into contact before going to the press.
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3) At present the Company is employing single wire technology wherein the pulp stock flows from the head box and gets distributed uniformly for further dewatering, pressing and drying to form a sheet of paper.
The twin wire technology is superior than the single wire technology due to the following factors: 1. Improves formation of paper. 2. Improves strength properties of paper namely, Burst factor, Tear factor, Tensile strength and Ring crush test values. 3. Reduces Cost of Production. The company will be able to derive the synergies of the existing plants and position itself as a largest Kraft paper manufacturer in south India by the installation of the plant. The market expectation for the increased production
Capacity, Production, Raw Material and Import Government has completely de-licensed the paper industry w.e.f. 17th July, 1997. The entrepreneurs are now required to file an Industrial Entrepreneur Memorandum with the Secretariat for Industrial Assistance for setting up a new paper mill or substantial expansion of the existing mill in permissible locations. The The indu indust stry ry is a prio priorit rity y indu indust stry ry for for fore foreig ign n co colla llabo bora rati tion on an and d fore foreig ign n eq equi uity ty partic participa ipatio tion n up to 51% receiv receives es aut automa omatic tic app approv roval al by Reserv Reserve e Ba Bank nk of Ind India. ia. Foreign investment even up to 100% is approved by FIPB on case to case basis. Several fiscal incentives have also been provided to the paper industry, particularly to those mills which are based on non-conventional raw material.
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There are, at present, about 515 units engaged in the manufacture of paper and pape pa perb rboa oard rds s an and d ne news wspr print int in Indi India. a. The The co coun untr try y is almo almost st se self lf-s -suf uffic ficie ient nt in manufa manufactu cture re of most most variet varieties ies of pap paper er an and d pap paperb erboa oards rds.. Import Import,, ho howev wever, er, is confined only to certain specialty papers. To meet part of its raw material needs, the industry has to rely on imported wood pulp and waste paper. The production of paper and paper board during the year 2001-02 is 31.62 lakh tonnes. The proportion proportion of non-wood non-wood raw material material base based d paper is increasin increasing g over the years. years. At present about 60.8 per cent of the total production is based on non-wood raw material and 39.2 per cent based on wood. The performance of the industry has been constrained due to high cost of production caused by inadequate availability and high cost of raw materials, power cost and concentration of mills in one particular area. Several policy measures have been initiated in recent years to remove the bottlenecks of availability of raw materials and infrastructu infrastructure re deve developme lopment. nt. To bridge bridge the gap due to short supply of raw materials, duty on pulp and waste paper and wood logs/chips have been reduced. The capacity utilization of the industry is low at 62% as about 194 paper mills, particularly small mills, are sick and/or lying closed. Several policy measures have been initiated in recent years. Imports of paper and paper products were growing over the years. However, it has decreased during 2000-2001 .
Demand and Supply gap in Paper Industry Indian paper industry is the 15th largest in the world and provides employment to 1.3mn people in the country contributing Rs.25bn to the Government. The industry
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has recorded a volume growth of CAGR of 5.47% over the last 3 years. In 2003-04, it recorded a volume growth of 6%, in line with the GDP growth. Indian paper industry has a 1:1 correlation with the economy. The demand for paper is linked to the GDP Growth. The government is planning to target a GDP Growth of about 10% in 2-3 years. With this increase in the GDP growth the paper sector is expected to record a similar growth rate. The Indian paper industry has an installed capacity of 6.7mn tons while, the effective capacity is estimated to be lower at 6.15mn tons. The industry produced 5.26mn tons of pa pape perr in 20 2003 03-0 -04. 4. News Newspr print int ca capa paci city ty in Indi India a is es estim timat ated ed at 1.12 1.12mn mn tons tons however, domestic production is only 0.59mn tons, while consumption of newsprint is 1.1mn tons. Favorable demand - supply scenario to keep prices firm The demand for paper is influenced by various macro-economic factors like national economic growth, industrial production, promotional expenditure, population growth and the Government’s allocation for the educational sector. Domestic demand for paper is expected to grow at a CAGR of 6-7%. India’s paper demand is expected to touch 8mn t.p.a by 2010. A leading global paper industry consultant projects a shortage of about 0.7mn tpa by 2010. Proposed capacity expansions:
Capa Capaci city ty ex expa pans nsion ions s (whi (which ch co cost st 50 50% % less less than than ne new w ca capa paci citi ties es)) ha have ve be been en announced by most players, but would take 1-2 years to be operational. Capacity expansions of over 600,000 tons have been announced by the 7 large players in the sector
WTO Impact WTO as discussed the implication of Indian Paper and Newsprint Industry as part of its negotiations and implications. The Indian Paper Industry has important place in the industrial landscape. The paper industry has a strong backward linkage with forests and environment on one hand and consumers of a variety of products on the other hand. The manufacture of paper through pulp of wood or of other fibrous cellulosic material has been discussed at length. However, recovery of waste or scrap for paper and paperboard manufacture has been looked at from different angle
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in the classification of products of Indian Paper Industry. In fact the paper industry whic which h are are ec eco o fri frien endl dly y imp imports orts lot lot of wast waste e pap ape er into into the the co coun untr try y in the the manufacturing of paper and paper board. Generally WTO implication is applicable to all the industries. How ever, in respect of paper industry where waste paper is the raw material and which is eco friendly, the impact is not harsh. SSPML is into manufacturing of paper out of the waste paper and is an eco friendly project.
GOVERNMENT REGULATIONS, PERMISSIONS PERMISSIONS & TAXES
1. Central Excise: Central Excise is levied @8% for the first 3500 MT production and thereafter @12% on the value of the invoice. The Company is availing permitted Modvat benefits as per Central Excise regulations. For import duty paid on waste paper procured from overseas the Company is entitled to adjust the entire duty paid component as that of Modvat credits.
2. VAT (Value Added Tax): VAT replaces the existing multipoint taxes levied by various states with effect from April ‘05. As that of other industries, the paper trade is also covered under VAT for domestic sales done in the state of Kerala. However for interstate sales CST is continued to be levied as per existing Government regulations.
3. Service Tax: Being classified as a manufacturing industry, the industry even for Job Work on conver con versio sion n bas basis is will will no nott be sub subjec jected ted to Servic Service e Tax requireme requirements nts.. A recent recent notification from Central Government also confirms such a stand.
4. Factory Licenses: All the licenses required under Municipality Act, Factories Act are obtained and duly renewed.
5. Pollution Control:
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Necessary permission under effluent discharge Act is obtained and the facilities required to maintain the permission are in place.
AVAILABILITY OF DOMESTIC WASTE PAPER Waste paper recovery system in India is very unorganized and unplanned . As a result, large quantities of waste paper get diverted for cheaper packaging and other uses or get destroyed as rubbish. Bulk of waste paper collected by street collectors in metropolitan cities goes to household paper bag manufacturers. Due to lack of any grading/ classification system in context of waste paper, no sorting or segregation is done at source and so most of the waste paper varieties are collected in commingled form. The probable sources of waste paper collection are as under: Waste
Paper Examples
Source Domestic refuse
Industrial refuse Office refuse
Trade refuse Road Sweeping
Newspaper, magazines, board cartons.
Corrugated boards, duplex & other packaging board, paper sacks etc. Ledger files and papers from Govt. offices, Universities & large business organizations. Boards trimmings from converters & packaging ing manufactures, paper savings from printers Newspapers and magazines are usually recycled directly as wrapping and packaging papers by the grocers and pretty traders and therefore they are not available for mills in their first rejection. Other fibrous domestic refuse probably find their way as road sweepings.
In In Indi dia, a, co coll llec ecti tion on of offi office ce refu refuse se ha has s no nott be been en ve very ry high high main mainly ly du due e to unavailability of a viable collection system. In practice, practice, more than 80% of the paper consumed in India is being collected, of which only 20% is being made available to paper pap er ind indust ustry ry and the rest rest
60% 60 % is
usuall usu ally y divert diverted ed
secondary uses such such as wrapping, wrapping, packing etc.
for oth other er
divers diversifi ified ed /
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The developed countries, which are the major players in paper recycling business, have hav e a well well def define ined d and pla planne nned d waste waste pap paper er gradin grading g system system in pla place, ce, which which facilitates the collection of recovered paper sorted in grades with a limited mixture of fiber types. Due to limited capacities of landfill sites and (municipal) incineration plants, increasing waste disposal costs and environmental awareness a wide range of legislat legislation ion / direct directive ives s in various various countri countries es have
been bee n impose imposed d which which has
promot promoted ed mater material ial recyc recycling ling an and d reduce reduced d furthe furtherr , the ge gener neratio ation n of waste waste tha thatt requires disposal in appropriate facilities. These regulations set responsibilities for taking back used paper products and packaging material independent of the public disposal system and recycling them. In India, however, no such regulations / law / directives are in force to promote use of recyclable resources, as a result of which the recovery of used paper is also low. As per the statistics statistics available available , the India Indian n paper industry industry is using more than 70% 70% of imported waste paper in its total waste paper consumption . The
general
issues
related with use of imported waste paper in Indian Paper Industry Industry are: Ø
Inconsistency in quality and varieties of waste paper grades.
Ø
High level of contamination i.e. prohibitive & out throws.
Ø
Price fluctuation in the international market.
Ø
High price for good quality waste paper i.e. low to negligible
contamination
level. Ø
High ash conte content nt in paper leading leading to low fiber yield / tpaper and generation of inorganic sludge.
ISSUES RELATED TO WASTE PAPER BASED MILLS
In sp spite ite of the fact that waste paper processing for pa paper per making making is considered to be an eco friendly process , there are certain technological technological & environmental issues still associated associated with waste pape paperr base based d mills mills which which needs needs to be be addres addressed sed to improve its environmental compatibility.
Technological Issues :
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The main objective of recycled fiber processing is the removal of contaminants and elimination of their effects as much as necessary to meet quality requirements. Removal Removal of conta contaminan minants ts makes makes recycled recycled fiber processing processing systems significan significantly tly more complex than systems for virgin fibers. There are several unit operations / stages sta ges viz. viz. slush slushing ing,, screen screening ing,, cleani cleaning, ng, flo flotat tation ion,, disper disperger ger etc etc.. to remove remove the contam con tamina inants nts from from recyc recycled led fib fiber er sto stock. ck. The tec techno hnolog logy y is well well est estab ablis lished hed to produce newsprint, packaging grades and fine papers and most of the mills in USA, Europe Europe hav have e sta statete-ofof-art art tec techno hnolog logy y for proce processi ssing ng of recycl recycled ed fib fiber. er. In Ind India, ia, however, most of the recycled fiber based mills do not have appropriate system configuration for efficient processing, as a result the quality quality of finished paper is low. low. The level of technology in majority of mills is obsolete. The operational efficiency of equipments and machines machines are are also considerably below the optimum level level . Due to lack of appropriate configurations, configurations, the amount amount of rejects generated are also high and and is a major source of solid waste generated in such mills .
Environmental Issues :
Among the environmental issues associated with recycled recycled fiber mills , solid waste waste disposal disposal and manageme management nt is the subject subject of main concern. concern.
Deinkined Deinkined
sludge sludge
generated from deinking plants in mills using printed waste paper for producing writing writing & printing printing grade grade of paper paper , consists consists of mainly fillers fillers and and coating coating pigments pigments,, fibers, fiber fines, printing inks and and adhesive components. components. A characteristic feature of the deinking sludge is its high ash content in the range of 40% - 70%. Traces of heavy metals metals may also also be present present in some cases. cases. In most of the cases the heavy heavy metal content is insignificant and sometimes even below the detection limit. The another another important important issue reported reported recently recently is the clandestine import of other waste like plastics, metal and cloth / rags etc (technically defined as prohibitive and out throws) along with waste paper. paper.
OBESRVATION & REMARKS :
Generally the waste paper being imported in the country are recovered in segregated form as per the request of the importer. However, some cases have been reported wherein municipal solid waste constituting of plastics, metal cans and cloth / rags etc (technically (technically defined defined as prohibitive and out out throws) have been illegally imported
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in grab of imported waste paper This has led to the need of defining / formulating the permissible limits for the contaminants like plastics, metal cans cans and cloth / rags etc. in the imported paper . At present, present, no data /guideline is available on this issue Therefore; it is recommended to undertake an indepth study on this issue so as to evolve permissible limits for prohibitive and outthrows in the imported waste paper consignments entering into the country .
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CORPORATE PROFILE M/s Shree Jagdambe Paper Mills Limited(SJPML), incorporated in July, 1980 as a private limited Company, commenced its commercial production of Semi Kraft Paper on single production line in March, 1982 with an installed capacity of 1950 M.T. per annum base based d on on agro agro residu residue. e.
In the the year 1985 1985-86 -86 the capacity capacity was was
increased to 3000 M.T. per annum & later in 1987-88 to 5000 M.T. per annum by adding certain balancing balancing equipments. In 1990, SJPML added added another production production Line and increased the capacity capacity to 10000 M.T. per annum. annum. In 1993-94 the plant has has been operated operated at 95% capa capacity city utilization utilization to give a productio production n of 9587 M.T. SJPML SJPML
has ha s
been bee n prom promote oted d by by Sh Shri ri Man Man Moha Mohan n Kuma Kumarr Goyal Goyal,,
Kumar Kumar Goyal, Goyal, Shri Shri Surend Surender er Kumar Kumar Goyal, Goyal, Shri Shri Parveen Kumar Goyal who have
Anil Anil
Shri Shri Rames Ramesh h
Kumar Kumar Goyal Goyal
professional background.
and an d
Shri Shri
SJPML has been
converted into a Limited Company on 28.12.94 and also enhanced its production capa ca paci city ty from from 10 1000 000 0 M. M.T. T.
At pres presen entt to 20 2000 000 0 M. M.T. T. pe perr an annu num m thro throug ugh h
Modernization- cum-Expansion Scheme. During the year 1994-95 an other sister unit of SJPML for manufactu manufacture re of Kraft Paper was incorporat incorporated ed as Shree Sita Ram Paper Mills Ltd., at Village Nanasanja Taluka Jagadia, Distt Bharuch Bharuch (Gujarat) with instal installed led capaci capacity ty of 200 20000 00 MT per ann annum. um. As acce ac cept pted ed in o ope pen n
mark market et,,
butt due bu due
produc productt of the company company is well
to Go Gove vern rnme ment nt pol polic icie ies s of of libe libera ralis lisin ing g
internation international al trade, trade, Import duty on Kraft Paper was reduced reduced resulting resulting dumping of Paper in India by multinational Companies and same also became a reason for down in production production for the year 2001 to 2003 2003.. Similarly Similarly Excise Excise Duty was also increased between 1994-95 to 2000-2001 from 0% to 5% and then to 8% and 16 % ( 2002-2003).
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BRIEF PARTICULARS OF THE COMPANY
The Company was incorporated under the name & style of M/s Jagdambe
Paper
Industries( Industries(P)Ltd P)Ltd., .,
dated
vide
certificate certificate
of incorporat incorporation ion
No.H-1072 No.H-10725 5
31.07.1980, with Registrar of Companies, Companies, Delhi & Haryana, Haryana, (New Delhi). The name of the the Comp Compan any y was was cha hang nged ed to Sh Shre ree e Ja Jagd gdam ambe be Pa Pape perr Mi Mill lls s (P) (P) Ltd. Ltd.,, on 10.02.1994. Now Now Company’s Company’s constitution has been changed to that of a Limited Compan Company y on 28. 28.12. 12.94. 94. The Compan Company y has General General of Technical Technical Developme Development, nt, In Indi dia a fo forr
manu manufa fact ctur urin ing g
No.102 No.1020(8 0(89)D 9)DLR LR
expa ex pans nsio ion n of ca capa paci city ty
itself itself with with
Direct Directora orate te
Delhi, Delhi, Ministry Ministry of Industry, Industry, Governmen Governmentt of
of Pa Pape perr
dated dat ed 17. 17.11. 11.198 1989 9
regist registere ered d
& for
to 20 2000 000 0 M. M.T. T.
Pape Pa perr 10000 100 00
Boar Bo ard d M.T. M.T.
vide vide
Regi Regist stra rati tion on
And memora memorandu ndum m for
Has Has be been en file filed d with with SIA SIA as
per pe r
acknowledgement dated 23.08.94.
BRIEF PARTICULARS ABOUT PROMOTERS OF THE COMPANY The Project was promoted by Shri Murli Dhar Jhuthran and Shri Ramesh Kumar Goyal. Shri Murli Dhar Jhuthran retired as Director in 1982. After then promoters were Shri Man Mohan Kumar Goyal, the Chairman of the Board of Directors, Sh Rame Ramesh sh
Kuma Ku marr
Goya Go yal, l, Ma Mana nagi ging ng
Director(Sa Director(Sales), les), Sh Anil Anil
Dire Direct ctor or,, Sh Su Sure rend nder er Ku Kuma marr Go Goya yal, l,
Kumar Goyal, Goyal, Director(P Director(Produc roduction), tion), Sh Parveen Parveen Kumar
Goyal, Director (Personnel). Shri Man Mohan Kumar Goyal started his career at the age of 17 years by joining joining his father's Brick Brick Kiln business. business. Being the eldest eldest son of late Sh Ram Saran Dass Goyal, he was involved in planning and managing all business activities of the family. He has hands-on experience experience in running brick kilns,
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Manufacturing of steel utensils, ice, managing agency, business of cement & match boxes, box es, pet petrol rol fillin filling g sta statio tion n an and d all proper propertie ties. s. In manufactur manufacturing ing of pape paperr and now he is
1980, 198 0,
he came came
into int o
the
an estab establishe lished d Industriali Industrialist st with a 14
years of experience in paper manufacturing. manufacturing. Sh Man Mohan Kumar Kumar Goyal resigned from director director ship of the company company w.e.f. 15.12.2001 15.12.2001 & shifted shifted to Gujarat Gujarat to look after day to day affairs of sister company Shree Sita Ram Paper Paper Mills Ltd.,
Shri Surender Kumar Goyal, B.A., started his career by joining family business. Later he
was instrumental in setting
up of M/s Aggarwal Ice Factory. In 1982, he
joined the captioned company as Director (Sales). He has been
instrumental in
developing network of dealers/agents and monitoring sales. Shri Anil Kumar Goyal, Chartered Accountant started his career by joining SJPML in the year 1984. Being an Accountant by profession he could read, analyze and plan the business to make the operations cost effective. Shri Parveen Kumar Goyal, B.A.started his career in 1981 at the age of 18 years and joined SJPML. Due to his strong human relation trits he was also given the responsibility of handling personnel functions and inducted as Director, in 1984. Sh Parveen Kumar Goyal company company
resigned from director ship of the
w.e.f. w.e.f. 15.12.2001 15.12.2001 & shifted shifted to Gujarat Gujarat to look after the day to day
affairs of sister company M/s Shree Sita Ram Paper Mills Ltd., Bharuch
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LOCATION OF MANUFACTURING PLANT AND ITS BRANCHES
SJPML has has free hold land land measuring measuring 126 kanal 13 marla, situated at Begu
Road,
Sirsa. Site is on metalled road about 2 K.M. from Sirsa. City in the the municipal limits nearest railway station is 3 K.M. at Sirsa.
Works sector:
Begu Road, Sirsa (Haryana)
:
Sector: Medium Scale Industry Registered Office : 161, Deepali, Pitampura, Punjabi Bagh, Delhi
Branch : Shree Jagdambe Paper Mills Ltd., 11, Jeet Building, Phase Ist, Ashok Vihar, Delhi
NAME OF THE SISTER COMPANIES/CONCERNS COMPANIES/CONCERNS a)
Shree Si Sita Ra Ram Pa Paper Mi Mills Ltd Ltd..,
Taluka Jagadia, Village NanaSanjha, Distt. Bharuch (Gujarat) Shree Sita Ram Paper Mills Ltd., incorporated in the year 1995 is sister company of Shree Jagdambe Paper Mills Ltd., involved in manufacturing of Multi Liner Craft Paper having production capacity of 20000 MT per annum.
b)
Shree Amba Paper (P) Ltd.,
73/4, Village Ghavera, Delhi c)
Ahmedabad Chemical Trading (P) Ltd.,
44, Ekjot Apartments, Maduban Chowk, New Delhi
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Both of two companies are the sister companies of Shree Jagdambe Paper Mills Ltd, based at Delhi, involved in trading for various types of paper and paper paper board.
OUR CUSTOMER A loyal loyal custom customer er bas base e is SJPML SJPML big bigges gestt qua qualit lity y end endors orseme ement. nt. The instit institutio utional nal customers comprise brand-enhancing names like Action Shoes, Micro Teck, Lakhani Shoes Ltd., among others.
CUSTOMER SERVICE The SJPML takes a holistic approach in the business of making paper and customer rela relati tion onsh ship ip en enjoy joys s a prio priorit rity y in this this.. The The SJPM SJPML L cu cust stom omer er se serv rvic ice e stan stands ds for for dependable quality, every possible choice and anytime product availability.
Convenience : We provide customers the benefit of staggered delivery so that they do not need to keep a large inventory at their end; this maximises working capital efficiency
weave the market marketing ing and manuf manufact acturin uring g fun functi ctions ons Customer Customer service service : We weave together. Quick and punctual delivery has added to customer convenience
PROCUREMENT OF RAW MATERIALS Main Ma in raw raw mate materia riall for for the the co comp mpan any y is co corru rruga gate ted d bo boxe xes/ s/wa wast ste e pa pape perr whic which h is purchased through local suppliers. Company has adopted inventory control system for purchase Raw material. Decision for making purchase is taken by the Executive Director (Purchase) after considering the indents for requirement of raw materials, received from the production department. Director (Purchase) is assisted by team of purchasers, who calls quotations from different suppliers of raw materials.
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RAW MATERIAL MANAGEMENT
Director (Purchase) after considering lowest quotations along with sample of raw material, place order for supply of raw material.
TESTING/CHECKING OF RAW MATERIAL
After receipt, consignment of raw material is weighted at company’s own weighing bridge. Weight as per company’s company’s weighing bridge is tallied with the weighing slip as as produced by the supplier of raw material. Bill of the material is also collected by the gate office for their nece necessary ssary inward inward material entries. Weight of the raw material is tallied with the weighing slip/bill of the supplier. If the weight is not tallied with the weighing slip/bill due to shortage, it is immediately informed to supplier/driver. A writt written en co cons nsen entt on the the ba back ck side side of bill bill is take taken n for for info inform rmat atio ion n of sh shor orta tage ge to supplier. Vehicle is then allowed to go to raw material godown for unloading with prior intimation to quality checking supervisors. Raw Material Quality Supervisor got unloaded the material in his presence. Sample from different bundles of raw material is taken for checking of quality/moisture etc. If, moisture is found in any bundle, sample of same is handed over to laboratory technician, who tested the percentage of moisture in the material. A report is being prepared by Lab. Lab. Technician for moisture moisture and other prohibited contents like plastic strips, kaccha material, reel core material etc. present in the lot of raw material. Report is also signed by Lab. Incharge as well as supplier of material. Weight of moisture/other prohibited contents present in the material is deducted from the total weight of material. Lab. Report so prepared, is forwarded to Director (Purchase) for his information and signature purpose. Copy of the report is then given to supplier of raw material. If, supplier does not accept weight of moisture/prohibited contents he is allowed to take his material back.
Copy Copy of th the e repo report rt,, is atta attach ched ed with with bill bill of su supp ppli lier er an and d ha hand nded ed ov over er to ga gate te department for entries in their inward receipt register. Rates of different type of raw materials are as under :-
19
1.
Corrugated Cartoons (Fresh)
Rs.8000/- PMT
2.
Corrugated Cartoons (used)
Rs.7000/-
,,
3.
Corrugated Cuttings (Fresh)
Rs.6800/-
,,
4.
Corrugated Cuttings (Old)
Rs.6500/-
,, ,,
5.
Media (Kaccha Material)
Rs.5500/-
,,
6.
Media (Core Pipes)
Rs.5000/-
,,
MANUFACTURING PROCESS ;
Paper is manufac manufactured tured
using using corrugat corrugated ed cartoon cartoons/was s/waste te
paper, pape r, Chemicals Chemicals and
water. The manufacturing process can be bifurcated in to four stages.
A) PULPING :
Corrugated Boxes/Waste Paper after cutting and dusting feed in to the pulpers for pulping. pulping. The waste waste paper paper can can directly directly be beaten beaten and and washed washed in the the beaters beaters for for pulping.
B) PREPARATORY TREATMENT OF STOCK :
Pulp Pu lp,, as it, is no nott fit fit for for be bein ing g co conv nver erte ted d in to pa pape perr an and d
must must under undergo go some some
preparatory preparatory treatment treatment depe dependin nding g on the end product. product. Before Before going to the the paper paper machin machine, e, the the stock stock
must must
be
prepai prepaid d unifo uniformly rmly with with a fixe fixed d thick thickne ness ss and and be be
screened screened and refined refined by by crushi crushing ng so that it may may be reduce reduce in to fixed thickness thickness with uniform properties in a uniform speed. The treatment is carried out in appratus called refiner and sizing agents like alum, dyes, loading materials are added in the process to develop its strength. The main flow of pulp which is freed from tailings in the vibrating vibrating screen screen and fine fine pulp sieved sieved out out from the the tailings tailings are put put together together and sent to the centricleaners centricleaners which work quite efficiently in removing removing fine dust.
20
C) PAPER MAKING :
Prior to going in to the paper making machine the stock which has gone through nece ne cess ssar ary y tre treat atme ment nts, s, is dilu dilute ted d in the the mixin mixing g
box, bo x, do down wn
to
the the
requ requir ired ed
consisten consistency cy with with the use use of back water gene generated rated in the the paper paper making making proces process. s. Similarly speaking, the paper paper making machine performs performs its function in this way :In the pulp stock which goes over travelling wire the fiber is separated from water & sheets of paper paper is formed. The The wet shee sheett is pressed dried dried and smoothene smoothened d by going throug through h several several sets of roll machine machines. s. To get M.G.Kra M.G.Kraft ft Paper, Paper, the sheet sheet is then passed through M.G.Dryer which imparts glaze to the paper. Paper is finally wound wound up by mean means s of pop-ree pop-reell machine machines. s. The The out put put of a paper paper machin machine e is determined by the trimmed width of paper, the speed of machine and grammage grammage of paper.
D)FINISHING OF PAPER :
Paper and board board inten intended ded for sale in reels and cut shee sheets ts is rewound rewound & cut to certain fixed measurements. Defective paper and and board board sheets are removed removed . The rejected produce is returned to pulping section and mixed into the main flow of pulp pulp stocks.
DISPATCHES
Reels so prepared, is then wrapped by plastic cloth and clipped with the help of plastic strips. Supervisor on duty mark a serial number, size and grammage on each reel for for the purpos purpose e of identifi identification cation..
Wrapped Wrapped reels reels are then then weighted weighted through through
electronic weighing scale. Weight as shown on the display is written in the reel by the supervisor. Supervisor also maintained a register in which he entered weight of each reel along with serial number of the reel. Reel is then shifted in finished goods godown from where it is dispatched as per orders received. Complete record of reels manufactured and reels dispatched are forwarded to account office.
21
QUALITY CONTROL :
SJPML has got got a well equipp equipped ed laborator laboratory y with all the the latest latest equipments equipments for for test cobb value, Tear Factor, Burst Factor, Consistency, Degree SR and Grammage etc.
NET WORK OF SALES
SJPML has a wide range of net work of dealers spread all over the India, which covers mostly all the states of India. CLIENTS
SJPML keeps stringent control over quality for consistent consistent quality which has helped it have clients like :a)
Micro Tek, Pa Parwanoo
b)
Action Shoes, De Delhi
c)
H.P. H.P.Co Cott tton on Tex exti tile les s Mil Mills ls Limit imited ed,, H His iss sar
d)
Baldeo Mange Lal, Ujjain
e)
Patel P Pa aper B Bo ox, U Ud daipur
f)
Perfect Pack Ltd., Faridabad
g)
Lak La khan anii Grou Group p of Ind Indus ustr trie ies, s, Farid arida aba bad d
h)
Ravi Sons, Chandigarh
i)
Kamal Boxes, Jalandhar
j)
Jay Ambe Overseas, Surat
k)
Industrial Packers, Daman
l)
Meiyappa Paper, Chennai
22
EMPLOYEES CAPACITY
Details of employees are as under :1.
Repair & Maintenance Staff
15
2.
Engineering & Manufacturing Staff
18
3.
Clerk
10
4.
Supervisors Connected with Process
5
5.
Supervisors Connected with Production
5
6.
Supervisor Connected with Despatches
5
7.
Supervisor Quality Checking
5
8.
Officer Staff
5
9.
Security
5
SHREE JAGDAMBE PAPER MILLS LTD., SIRSA PROCESS FLOW DIAGRAM
Waste Paper Along with 12% Normal Moisture,
23
Stapple Pins & Adhesives)
CONVEYOR
PULPER
VACCUM BOXES
PRESS NO.1
WIRE PART
PRESS NO.2
HEAD BOX SAND TRAP
DUMPING CHEST HIGH DENSITY CLEANER
TURBO
THICKNER
DRYER CENTI CLEANER
M.G.DRUM FLOW BOX MACHINE
MIXING CHEST CHEST NO.2
ALUM ROSIN
REELER
REWINDER
REFINER
FINISH PRODUCT
Solid Waste to Boiler/ETP
REMMUNERATION OF WHOLE TIME DIRECTOR Sri Surinder Kumar Goyal Sri Surinder Kumar Goyal a Post Graduate in Commerce and has been in the services of the Company as Director (Sales) since the incorporation of the Company. He will be entitled to the following remuneration as fixed at the Board meeting Committee and as approved at the Annual General Meeting of the Shareholders of the Company , in accordance with the provisions of Section 311, 198, 269 and 309 read with Schedule XIII and all other applicable provisions if any of the Companies Act, 1956 or any statutory modifications or re-enactment thereof.
24
1.
Salary Rs. 30000/- per month
2.
Commission : N.a.
3.
Perquisites House rent allowance at the rate of 50% (fifty percentage) of the Salary Medical expenses:- Medical expenses for the Director and his Family subject to a ceiling of one month’s salary in a year or three month’s salary over a period of of three years Personal Accident insurance – an amount of the annual premium of which does not exceed Rs. 12000/Gratuity payable – Not to exceed half a month’s salary for each completed year year of serv servic ice. e. Prov Provis isio ion n of Car Car for for use use on Comp Compan any’ y’s s busi busine ness ss and and Telephone at residence Perquisites shall be evaluated as per Income tax rules, 1962 wherever applicable.
Sri Anil Kumar Goyal
Sri Anil Kumar Goyal Goyal a Chartered Accountant Accountant is in the services of the Company Company as Director (Finance) since the incorporation of the Company. He will be entitled to the following remuneration as fixed at the Board meeting Committee and as approved at the Annual General Meeting of the Shareholders of the Company , in accordance with the provisions of Section 311, 198, 269 and 309 read with Schedule XIII and all other oth er ap appli plicab cable le provis provision ions s if any of the Compan Companies ies Act, Act, 195 1956 6 or any statutor statutory y modifications or re-enactment thereof. 1.
Salary Rs. 30000/- per month
2.
Commission : N.a.
3.
Perquisites House rent allowance at the rate of 50% (fifty percentage) of the Salary Medical expenses:- Medical expenses for the Director
25
and his Family subject to a ceiling of one month’s salary in a year or three month’s salary over a period of of three years Personal Accident insurance – an amount of the annual premium of which does not exceed Rs. 12000/Gratuity payable – Not to exceed half a month’s salary for each completed year year of serv servic ice. e. Prov Provis isio ion n of Car Car for for use use on Comp Compan any’ y’s s busi busine ness ss and and Telephone at residence Perquisites shall be evaluated as per Income tax rules, 1962 wherever applicable.
Sri Rakesh Kumar Goyal
Sri Rakesh Kumar Goyal a Graduate in Commerce and has been in the services of the the Comp ompany any as Dire Direct ctor or sinc ince 1996 1996.. He will will be enti entitl tle ed to th the e fo foll llow owin ing g remuneration as fixed at the Board meeting Committee and as approved at the Annual General Meeting of the Shareholders of the Company , in accordance with the provisions of Section 311, 198, 269 and 309 read with Schedule XIII and all other ap appl plic icab able le prov provis isio ions ns if an any y of the the Comp Compan anie ies s Act, Act, 19 1956 56 or an any y stat statut utor ory y modifications or re-enactment thereof.
1.
Salary Rs. 25000/- per month
2.
Commission : N.a.
3.
Perquisites House rent allowance at the rate of 30% (fifty percentage) of the Salary Medical expenses:- Medical expenses for the Director and his Family subject to a ceiling of one month’s salary in a year or three month’s salary over a period of of three years
26
Personal Accident insurance – an amount of the annual premium of which does not exceed Rs. 12000/Gratuity payable – Not to exceed half a month’s salary for each completed year ye ar of se serv rvic ice. e. Prov Provis isio ion n of Car Car for for us use e on Comp Compan any’ y’s s bu busi sine ness ss an and d Telephone at residence Perquisites shall be evaluated as per Income tax rules, 1962 wherever applicable.
Sri Manoj Kumar Goyal
Sri Manoj Kumar Goyal a Graduate in Commerce and has been in the services of the Company as Director since 2000. He will be entitled to the following remuneration as fixed at the Board meeting Committee and as approved at the Annual General Meeting of the Shareholders of the Company , in accordance with the provisions of Section 311, 198, 269 and 309 read with Schedule XIII and all other applicable provisions if any of the Companies Act, 1956 or any statutory modifications or reenactment thereof. 1.
Salary Rs. 20000/- per month
2.
Commission : N.a.
3.
Perquisites House rent allowance at the rate of 30% (fifty percentage) of the Salary Medical expenses:- Medical expenses for the Director and his Family subject to a ceiling of one month’s salary in a year or three month’s salary over a period of of three years Personal Accident insurance – an amount of the annual premium of which does not exceed Rs. 12000/Gratuity payable – Not to exceed half a month’s salary for each completed year ye ar of se serv rvic ice. e. Prov Provis isio ion n of Car Car for for us use e on Comp Compan any’ y’s s bu busi sine ness ss an and d
27
Telephone at residence Perquisites shall be evaluated as per Income tax rules, 1962 wherever applicable.
DETAILOF DIFFERENT DEPARTMENTS
Finance/Administration Department Mr. Anil Goyal Goyal is a Chartered Chartered Accounta Accountant, nt, has a distinguish distinguished ed career career in the area of Corporate Finance and brings with him a unique combination of skills from Accounting, Costing, Secretarial Services and Financial Management. He started his career in 1985 and added to his profile significant skills in the areas of Taxation, Costing, Insurance, Working Capital Management, Project funding funding by way of debt from multinatio multinational nal agencies, agencies, raising raising equity etc. Ever since he joined SJPML he has been instrumental in bringing in the financial discip disciplin line e and ana analys lysis is tha thatt he helpe lped d the Man Manage agemen mentt to tak take e variou various s cost cost effective effective decisions. decisions. He has made significant significant contributions contributions in identifying identifying the financial institutions for sourcing the funds for the Mill Development Plan.
Accounts Department Accounts Department has also been supervised by Sh Anil Goyal, Director Finance Finance unde underr assistance assistance of Accounts Accounts Manager & Accounts Accounts Assistanc Assistances. es. Under his supervision and new ideas company has a modern and high-tech accounting software and a well established computer lab.
Purchase Department Purc Pu rcha hase se of raw raw mate materi rial al is su supe perv rvis ised ed by Sh Ma Mano nojj Go Goya yal, l, Dire Direct ctor or Purcha Purchase se.. Direct Director or Purcha Purchase se is assist assisted ed by Purcha Purchase se Man Manage agerr and Raw Material Quality Managers.
Production Department Production Production is supervis supervised ed by Sh Rakesh Rakesh Goyal, Director Director Productio Production. n. He is assist assisted ed by the Produc Productio tion n Man Manage agerr and Plant Sup Superv erviso isors. rs. He is the ke key y
28
contrib con tributo utorr to the proces process s of dev develo elopin ping g the Qua Quality lity Assura Assurance nce and R&D Functions in the organization. organization. His contribution in customer development development and customize customized d product development development has been unparalleled. unparalleled. Later on with his abilities in technical and administrative skills, took over the role of managing the Production Operations. Operations. He is specialized in the areas of Technical Technical Sales, Custom Customer er servic service, e, and Product Product dev develo elopme pment. nt. He is the critic critical al In-hous In-house e Resource for various Learning Events being conducted in various technical areas.
Dispatch Department Dispatch Dispatch Department Department has also also been supervised supervised by Sh Rakesh Rakesh Goyal. He is assisted by supervisors and dispatch clerks.
HR. Department SJPML’ SJPML’s s Human Human Resour Resource ce Proces Processes ses are rooted rooted in bus busine iness ss priorit priorities ies,, market realities and long term oriented. Inherent in them are the qualities like innova inn ovatio tion, n, con contin tinuou uous s lea learni rning ng and improv improveme ement nt in the work work proces processes ses,, talent identification and and nurturing. SJPML through through its concerted concerted efforts aims at becoming the most preferred employer in the Industry and create one of the best places to work in the manufacturing sector.
Our HR processes stem from the faith in Human Potential and its Creative Power. Our work culture that enable its Human Resources enjoy professional freedom. Our Learning Center is a forum where unique learning events take place as a part of the process of institutionalization of continuous learning.
The The co comp mpen ensa sati tion on pa pack ckag age e of the the SJPM SJPML L matc matche hes s with with the the Indu Indust stry ry Standards with qualities of flexibility, valuing talent and encouraging career growth.
29
Our Performance Management System encourages its Human Resources to add value and increase their contribution to the growth of the organization on a continuous basis thereby guarantees timely reward and recognition.
Maintenance Department Exte Extens nsiv ive e moni monito tori ring ng,, an anal alys ysis is,, an and d co cont ntro roll woul would d op opti timi mize ze mechan mechanica ical/e l/elec lectri trical cal system systems, s, manage manage ene energy rgy usa usage, ge, pin pinpoi point nt proble problem m sources, and avoid unnecessary downtime. For electrical maintenance SJPML has flexible solution with comprehensive energy ene rgy con consu sumpt mption ion log logs s and immedi immediate ate access access to a range range of ele electr ctrica icall parame parameter ters, s, presen presentin ting g inf inform ormati ation on remote remotely ly via the compan company's y's existi existing ng computer network. Power Measurement offered the right set of capabilities with its energy management software, installed on distributed workstations, and a network of intelligent power meters. The system proved to be a valuable aid in the design and operation of electrical installations. Further operational savings are being realized, especially related to fast alarm response, and the system system's 's modula modularr archit architect ecture ure fac facilit ilitate ates s aff afford ordabl able e growth growth of all ene energy rgy management applications.
Energy Conservation SJPML SJPML has always always been con concer cerned ned an and d commit committed ted to improv improve e the mill mill ene energy rgy performance levels continuously. Basically because it realizes that natural energy resources available are finite with no way of replenishing the quantum consumed and also heavy investments are required for energy sector for meeting the demands and these resources are to be consumed with prudence to conserve the energy. For SJPML, conservation of energy has become a way of life. It reflects and manifests itself in all the endeavors. SJPML realizes that this not only is a means to improve competitiveness, enhance profitability but also is a source of moral responsibility.
30
To achieve the above objectives of energy performance, SJPML has constituted an independent Energy Conservation Department and engaged reputed proven “Energy Consultants” as early as in 1987 for energy audit, 1990-91, 1996-97, 2001-02 for detailed energy audit with mass; and energy balance and in 2007 for energy audit. These studies are conducted for identification and implementation of energy saving proposals, reduction in energy cost and wastage with improved housekeeping and monitoring monitoring practices. practices. The department department is best bestowed owed with the functions of bringing bringing awaren awareness ess of; import importanc ance e of ene energy rgy to the employ employees ees by co condu nducti cting ng in hou house se training training programs, programs, by organizing organizing energy conservati conservation on week celebrations, celebrations, Energy Energy Conferences, etc.
The The En Ener ergy gy Cons Conser erva vati tion on de depa part rtme ment nt prep prepar ares es an and d moni monito tors rs da dail ily y en ener ergy gy performance of the mills through computerized daily energy performance reporting system. SJPML has installed energy meters and measurement devices for all energy inputs like power, water, steam, fuels, compressed air and condensate return. The energy performance report indicates the figures of today and till date against best achieved norms for immediate comparison and for identification of variances on total and specific energy consumption figures of various sections of the mill for all the above energy inputs.
These daily reports are put for specific discussions on energy performance in daily production meetings, for taking effective corrective actions. The detailed monthly energy performance reports are also presented in monthly executive performance review meetings for identifying areas of improvement and for making; necessary exclusive decisions.
Energy Consumption:
SJPML, being an integrated pulp and paper mill, consumes steam and power for the production. Steam is generated not only for the process, but also captive power generation. The fuel for steam generation is husk, the solid waste dust generated in the process is also used as fuel.
31
The Mills has operating TG sets for co-generation, Double-Extraction-Condensing type of 12 MW capacity and fully condensing set of 5 MW capacity. The 12 MW and 5 MW steam turbo generator sets are operated continuously.
In the the ye year ar 20 2006 06-2 -200 007 7 the the fuel fuel co cons nsum umed ed in the the bo boil iler ers s for for proc proces ess s stea steam m requirements and the power generation is a total of 197274 Tons out of which 108579 tons is used for process steam 88695 tons for power generation.
Ener En ergy gy Cons Conser erva vati tion on is an on ongo goin ing g proc proces ess. s. Real Realiz izin ing g the the ne need ed for for en ener ergy gy conser con serva vatio tion, n, SJPML SJPML put puts s its eff effort orts s for improv improving ing the en energ ergy y perfor performan mance ce on continuous basis.
Description of the energy conservation schemes
Installation of energy efficient booster water pump in paper machines.
Mill water header pressure is maintained at 2.6 kg/cm2. The pressure could not be reduced to 2.2 kg/cm2 due to bleach plants pressure requirement at 2.5 kg/cm2. Booster water pumps of 2.5 kg/cm2 pressure are installed in bleach plant and mill water pressure is reduced to 2.2 kg/cm2. Investment is Rs. 6.5 lakhs, savings Rs. 4.43 lakhs per annum and simple payback period is 8 months.
Conversion of non-lubricating type compressor into lubricating type and installation in paper machines:
Comp Compre ress ssor ors s are are un uniti itize zed d in po powe werr bloc block k area area . The The remo remove ved d co comp mpre ress ssor or is converted to non-lubricating type and installed in paper machines there by unitizing four numbers of compressors in that area.
Installation of energy efficient vacuum pumps in paper machines:
32
Paper Machine commissioned in 1966 has old version vacuum pumps of N14 E model. Two pumps are replaced with Nash make energy efficient pumps of 904 M2 model.
SAFETY & ACCIDENT PREVENTION 1.
The The Sa Safe fety ty and and Acci Accide dent nt Prev Preven enti tion on acti activi viti ties es at SJPML SJPML ar are e moni monito tore red d by a part pa rtic icip ipat ativ ive e
safe sa fety ty co comm mmit itte tee e
with with eq equa uall
numb nu mber er of memb member ers s
from from
Management and Workmen. This committee is in existence since 1976. There are 3 department level safety sub-committees, which look in to local level safety saf ety and accide accident nt preve preventio ntion n ac activ tivitie ities s in co colla llabor borati ation on with the Saf Safety ety Commit Committee tee and Saf Safety ety Depart Departmen ment. t. The Saf Safety ety Depart Departmen mentt is manned manned by qualified safety officers and other administrative assistance.
1.
Acci Accid dent ent Repo Report rtin ing g and Inv Investi estiga gati tion on :
All the accidents and near miss accidents are reported and investigated and reviewed by the Safety Committee. The accident data is analyzed and Safety Performance is measured monthly, quarterly and yearly and communicated to concerned depts. and higher authorities.
2.
Identification of Hazards :
Frequent inspections are being carried out by using checklists. The Safety Committee and Sub-committees also inspect the plants regularly.
3.
Safety Systems :
Safety Work Permit System and Danger Tag System are in use for carrying out repair and maintenance works, hot works in fire prone areas, entry in to confined space, work on roof, excavation, etc.
4.
Safety Training :
33
General and need based training is given regularly to all employees including cont. workmen
5.
Motivation :
National Safety Day is celebrated every year. Many competitions like slogans, stories, posters, essays, etc. are organized on the occasion of National Safety Day Celebrations every year. An accident reduction contest is organized. . 6.
Publicity :
Poster Posters, s, Slogan Slogans, s, Bullet Bulletins ins,, etc etc.. are displa displayed yed throug through h out pla plant nt Saf Safety ety Magazine is published
7.
Personal Protective Equipment :
Shoe Sh oes s are are prov provid ided ed on once ce in a ye year ar to all all empl employ oyee ees s inclu includi ding ng co cont ntra ract ct workmen Helmets are provided to all employees All other Personal Protective Equipment is issued based on the need Some equipment like Self Contained Breathing Apparatus; Canister Masks, PVC suits etc. are kept in the depts. for use whenever and wherever those are needed
8.
Eme Emerge rgency ncy Pla Plann nnin ing g & Pre Prepa parredn edness ess & Re Respon ponse
Emergency Plan is made and copies distributed to all concerned personnel. Periodic mock drills are being organized Emer Emerge genc ncy y co cont ntro roll ce cent nters ers es esta tabl blis ishe hed. d. Acti Active ve role role is be bein ing g play played ed in preparation of Off Site Emergency Plan being made by District Emergency Authority.
9.
Occupational Health :
Occupational Health Centre is established. One doctors and 2 nurses are work workin ing g in Occu Occupa pati tion onal al Heal Health th Cent Centre re.. It is op oper erat ated ed roun round d the the cloc clock k Periodical medical exams are being carried out for the identified personnel.
34
This includes X-rays, Clinical examination; Blood exam; Lung function test; audio metric, stool exam; eye exam as per the requirement under Factories Act 1948
ENVIRONMENT CELL AT SJPML
SJPML has established a separate, dedicated ENVIRONMENT CELL for Water and Air pollution abatement, which indicates the commitment of the Industry in controlling the pollution.
ENVIRONMENT LABORATORY:
Enviro Environme nment nt Cell Cell is hav having ing an exclus exclusive ive Enviro Environme nment nt La Labor borato atory ry equ equipp ipped ed with with modern modern monito monitorin ring/t g/test esting ing fac facilit ilities ies.. Testin Testing g fac facilit ilities ies av avail ailabl able e at Enviro Environme nment nt Laboratory.
•
Water and Waste Water Testing
•
AOX Testing
•
Stack Monitoring Facilities
•
Ambient Air Quality Monitoring
•
Meteorological Station with automatic data logger
The Environmental issues are reviewed in the daily coordination meeting chaired by Vice President (Operations).
WATER POLLUTANTS AND TREATMENT MEASURES WASTE
WATER TREATMENT:
The main pollutants in the effluent discharged are Suspended Solids, B.O.D, and C.O.D etc. The wastewater from the mills is treated in Effluent Treatment Plant consisting of Primary Treatment to remove the suspended solids and Secondary
35
Treatment (Activated Sludge Process) to remove B.O.D and C.O.D and then treated by Land Treatment process to remove even the Colour of the effluents. SJPML is the only mill discharging effluents upstream and drawing water from down stream.
PRIMARY TREATMENT:
Wastewater is passed through bar screens and perforated screens to remove any foreign material and pumped to primary clarifiers (2 Nos.). of each 7500 M 3. The settleable solids are removed from the bottom and clarified effluent from the top of the clarifier is taken to Secondary Treatment.
SECONDARY TREATMENT (ACTIVATED SLUDGE PROCESS):
The effluent from the Primary Treatment is taken to an aeration tank of 25000 M 3 volume. There are 11 Nos. of mechanical surface aerators, each of 75 HP. Nutrients like Urea and SSP (Single Super Phosphate), are dosed in to the aeration tank as food to the bacteria. From the aeration tank the effluent is taken to the secondary clar clarifi ifier ers s (2 Nos. Nos.)) of 60 6000 00 M3 eac each. h. The eff efflue luent nt aft after er Second Secondary ary Treatm Treatment ent is pumped to Land Treatment.
LAND TREATMENT:
It is a well recognized fact that top layer of the soil maintains a Micro Environment within which soil Flora and Fauna decompose varieties of organic matter. Thus, top layer of soil can be utilized for the treatment of Biodegradable Organic Waste water. Several conventional (natural, physical and biological) treatment processes occur in Land Treatment. Considering such capability of land for treating wastewater, land treatment is well recognized as Living Filter all over the World. As wastewater is discharged on land for treatment, part of it infiltrates down wards and part evaporates and part gets transpired by Plants. The remaining portion gets utilized under the influence of Land as Living Filter.
The removal of constituen constituents ts from wastewater wastewater by filtering filtering and straining straining action of soil are are ex exce celle llent nt in this this RI syst system em.. B.O. B.O.D, D, T.S. T.S.S S & Faec Faecal al Coli Colifo form rm are are almo almost st completely removed. It is also observed that the effluents after percolation through land is void of colour. The soil seems to be working as colour removal media which is
36
otherwise prohibitively expensive treatment. This is an additional benefit achieved through Land Treatment.
AIR POLLUTION CONTROL MEASURES:
In Paper Manufacturing Process steam is required at various stages. For generating the steam the Mills has installed five Coal Fired Boilers and three Recovery Boilers, where in the black liquor is fired in the furnace to recover and reuse the valuable chemical in the process. The Mill also installed one Rotary Lime Kiln where the lime sludge (CaCO3) is burnt to get burnt lime l ime (CaO) to reuse in the Causticizing Process.
ELECTROSTATIC PRECIPITATORS:
The emissions from the boilers contain dust particles (Suspended Particulate Matter, SPM) and contain gases like Sulphur dioxide and Hydrogen sulphide etc,. In order to control the dust particles and gases from the boilers the Mills has installed most modern sophisticated Electro Static Precipitators as Pollution Control Equipments to all the nine stacks.
INCINERATION SYSTEM:
The The Comp Compan any y ha has s take taken n an alt altog oget ethe herr diff differ eren entt ap appr proa oach ch to elim elimin inat ate e od odou our r completely and installed “ Non-Condensable Gases Handling System” consisting of Collection, Transportation and Incineration of NCG. The system is first of its kind in Pulp and Paper Industry in India to control Odour problem.
Thus the Mill is fully conscious of its social obligations towards the abatement of air pollution and had spent quite a lot of money towards pollution control measures and striving hard and putting all its sincere efforts for minimizing the pollution from the mills.
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RECOMMENDATIONS RECOMMENDATIONS OR SUGGESTIONS During my training in SJPML, I have got exposure of so many things related to this field. I am very grateful to SJPML to offer offer me such an opportunity. I feel that it is my responsibility to recommend some suggestions these will ultimately for the benefit of the company. Some important i mportant recommendation or suggestions are as under:1.
SJPM SJPML L sho shoul uld d chec check k its its sup suppl ply y & dis distr trib ibut utio ion n chan channe nels ls.. Pres Presen ently tly co comp mpan any y is selling their product through commission commission agents network. network. If company, sell its prod produc ucts ts thro throug ugh h ag agen enci cies es/d /dea ealer ler ne netw twor ork, k, co comp mpan any y co coul uld d ge gett be bett tter er realisation.
2.
SJPM SJPML L mostl mostly y deals deals in cash cash paym paymen ent/ t/ad adva vanc nce e payme payment nt tran transa sact ctio ions ns.. If the the compan company y allows allows some some credit credit period period to the co consi nsigno gnor, r, sales sales realis realisati ation on & marketing position of the will automatically improve.
3.
Pape Pa perr manu manufa fact ctur ured ed by by the the comp compan any y is main mainly ly us used by by the the corr corrug ugat ated ed uni units ts for manufacture of corrugated boxed used for packaging. Presently improved global market demands demands corrugation in different colours & different patterns. patterns. If the company install such equipment’s through which they can manufacture pack pa ckin ing g pa pape perr in dif diffe fere rent nt co colo lour urs, s, mark market et po posi siti tion on of the the co comp mpan any y will will improve globally.
4.
Pres Presen entl tly y comp compa any do does not not ac accep eptt any any orde orderr whic which h is les less than than 10 10 M.T. M.T. There are many consumers with small-corrugated units in surroundings areas.
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But due to policy of company they are not able to purchase product of the company. So, it is necessary company should change its policy to enhance its infrastructure. 5.
Presently Company does not have any sales les in south region ion. Company should advertise its product in south region to achieve better orders.
6.
Comp Compan anie ies s Of Offi fice cerr shou should ld hel held d regu regula larr visi visits ts to to thei theirr clie client nts, s, end end use userr with with this this they are able to find out any problem prevailing in market.
7.
Com Compa pany ny sho shou uld imp impro rov ve its its pack packin ing g sect sectiion on..
Pres Prese ently tly reel reels s of pap pape er
manufactured are packed in Hession Hession cloth(Jute). It is better for for the company if they start using using plastic plastic cloth for packing packing of reels which which is much cheaper cheaper & strong than hession cloth
LIMITATIONS:
The extent to which study is reliable, it is important to note the limitations under which the study has been conducted. These limitations are as follows:10.. 10
Due Due to short shortag age e of time time it was not not possi possibl ble e to cover cover all all the netw networ ork k of the Company.
11.
It bein being g my first first atte attempt mpt to unde underta rtake ke suc such h a study study,, thus thus inex inexper perien ience ce is is al also so a obstacle to accomplish the project in proper way.
12.. 12
It is also also diff diffic icul ultt for for me to get infor informa mati tion on abou aboutt so some me othe otherr co conf nfid iden enti tial al clients of the company.
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