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TNPL COMPANY
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TNPL COMPANY Tamil Nadu Newsprint And Paper Limited(TNPL) was established by the government of Tamilnadu in the year 1979 April 16 th , as a ´Public Limited companyµ under the provision of the companies act 1956. The primary object of the company is to produce newsprint and printing & writing paper using using bagasse as a primary raw material. TNPL possesses a rich pedigree. Its milestone project was promoted by the Government of TamilNadu with financial assistance from the World Bank in 1979. TNPL globally pioneered the manufacture of newsprint from bagasse (a renewable resource obtained as a residue from the manufacture of sugar). In doing
so, the company redefined the technology of the manufacture of printing and writing paper from bagasse. As a result, TNPL·S installed capacity of 2, 30,000 tpa represents the world·s capacity among non-wood non -wood based mills mills today and is the largest single location integrated paper mill in India. TNPL'S investment in state -of-the-art machines and the consequent technology edge have translated into a high quality and large volume of finished paper, customized closely to user requirements. TNPL's investment in state-of-the-art machines and the consequent technology edge have translated into a high quality and large volume of finished paper, customized closely to user requirements.
4 Tnpl business
The company is in the business of manufacturing and marketing of newsprint and print & writing papers. The products are being marketed throught the and also being exported to 20 countries around the world.
The initial capacity of the plant was 90,000tpa of newsprint and printing & writing paper which commenced production in the year1985.The capacity of the company was doubled to 1,80,000tpa in january1996 after implementation of the first expansion project. Further, the capacity has has been enhanced to 2,30,000tpa in the April2003 through upgradation of paper machineries.
The factory is situated at kagithapuram, in karur district of Tamil Nadu. And the registered office of the company is at 67,mount road, Guindy,Chennai32.
. View of factory at Kagithapuram,Ka Kagithapuram,Karur rur(dt),tamillnadu (dt),tamillnadu register office in Chennai,tamilnadu
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so, the company redefined the technology of the manufacture of printing and writing paper from bagasse. As a result, TNPL·S installed capacity of 2, 30,000 tpa represents the world·s capacity among non-wood non -wood based mills mills today and is the largest single location integrated paper mill in India. TNPL'S investment in state -of-the-art machines and the consequent technology edge have translated into a high quality and large volume of finished paper, customized closely to user requirements. TNPL's investment in state-of-the-art machines and the consequent technology edge have translated into a high quality and large volume of finished paper, customized closely to user requirements.
4 Tnpl business
The company is in the business of manufacturing and marketing of newsprint and print & writing papers. The products are being marketed throught the and also being exported to 20 countries around the world.
The initial capacity of the plant was 90,000tpa of newsprint and printing & writing paper which commenced production in the year1985.The capacity of the company was doubled to 1,80,000tpa in january1996 after implementation of the first expansion project. Further, the capacity has has been enhanced to 2,30,000tpa in the April2003 through upgradation of paper machineries.
The factory is situated at kagithapuram, in karur district of Tamil Nadu. And the registered office of the company is at 67,mount road, Guindy,Chennai32.
. View of factory at Kagithapuram,Ka Kagithapuram,Karur rur(dt),tamillnadu (dt),tamillnadu register office in Chennai,tamilnadu
view of
TNPL VISION
T o be the market leader in the manufacture of world
class eco -friendly
papers by adopting innovative technologies and plans for the sustainable development. Tnpl mission
To attain leadership in paper technology. To promote the usge of bagasse in the manuf acture
of newsprint and
printing & writing paper.
To minimize the environment impact and to become an environment eco friendly products.
Tnpl record TNPL has recorded highest production of 30,248mts of ´TNPLcopier papersµ during2004-2005. The growth works out to 21% against the industry average growth of 15%.TNPL is poised to achive 40,000mts of branded copier production 2005-20006.
Iso-certification
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FEATURES
OF MILL
A view of TNPL factory
KEY FEAT RES OF MILL: 1
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The largest bagasse based plant in the World and a mill with largest production capacity in India, at a single location. Appropriate for India, which is one of the largest sugarcane producers in the World. The only paper mill in India assisted by the World Bank Doubled the capacity within a period of 10 years from inception State-of-the-Art paper machines with built in flexibility for manufacturing both newsprint and printing & writing papers in the same machine. Unique arrangement with the sugarmills for sourcing the raw material. in the form of exchange of steam / fuel for bagasse.
Paper machine-I
Paper machine-II
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´T P has gro n fro an ini ial capaci of 90 000 MT p rann in th year 1985 to the current level of 245 000 MT per annum through capacity expansion 8
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and machine upgrades. TNPL has continuously worked towards betterment of its bagasse based paper technology an d maintenance of its status as a globally competitive low cost producer. Life Cycle Extension: The Company has implemented the Life Cycle Extension of Paper Machine-I during April 2009. The old head box has been replaced with a new stateof-the-art head box. Improvements have been carried out in press frames, size press, pope reel and winder. Mill Development Plan: The Company has implemented the Mill Development Plan in May 2008. Under the Mill Development Plan, a new 300 tpd stateof- the-art hard wood pulp line with ECF bleaching and a 500 tpd ECF bleach plant for chemical bagasse pulp line have been installed. A new recovery boiler of 1300 tpa, a falling film evaporator of 350 tpd water evaporation capacity, a new 20 MW turbo generator and a fully integrated 15 tpd Chlorine-di-Oxide . With the implementation of the Mill Development Plan, the Company has moved over from conventional bleaching to Elemental Chlorine Free (ECF) bleaching. This has made the plant more environmental compliant, operationally efficient and cost effective.
Mill Expansion Plan: The Company has embarked upon the Mill Expansion Plan increasing the paper production capacity from 245,000 tpa to 400,000 tpa. The Mill Expansion Plan involves installation of a state-of-the-art Paper Machine with a production capacity of 155,000 tpa of fine paper, backwardintegration of chemical bagasse pulp line by installing high efficient washers for the brown stock pulp with oxygen delignification, closing the brown loop to enhance the environmental performance and installing a multi-fuel boiler with steam generation capacity of 125 tph. The project is expected to be completed by 30.6.2010. De-Inking Plant: Taking into account the additional requirement of pulp post implementation of Mill Expansion Plan, the Company has planned to install a state-of-the-art De-Inking Plant of a capacity of 300 tpd.The project will be taken up for implementation during the year and completed by September 2011. Revamping of Steam and Power System: To improvethe energy efficiency, the Company has proposed to replace three old low pressure boilers of a total capaci ty of 180 tph with a new 120 tph high pressure boiler. In addition, the Company has proposed to replace two old TG sets of a total capacity of 18 MW with a new high efficient TG of 40 MW capacity to augment the in-house power generation to meet the additional requirement of
po er. The project will be taken up f or implementation during the year and completed by September 2011. C
L imeSludgeManagement: The lime sludge generation from the recovery cycle and the f ly ash generated from the power boilers are issues of concern in solid waste management. An innovative solution of combining these two and converting them into high grade cement has been drawn through installation of a mini cement plant within the factory. The procurement action f or the machinery has been initiated and the Company is in the process of obtaining the environmental clearance.
Paper production capacity(tpa) Paper production capacity(tpa) 400000
245000 230000
180000
90000
1985
1996
2002
2008
2010
Environment protection of >>>>>>>TNPL<<<<<<<<
Environment Protection
Environment Protection and Management are integral part of the Company's activities. The Company has taken several measures for protecting the environment in line with its commitment for ustainable development. In its choice of raw materials, sources of energy and production processes, as well as in product development, the objective is to minimize the impact on environment. Treated effluent water conforming to the Pollution Control Board norms is utilized for irrigating the once barren lands near the mill. About 1665 acres of arid lands are irrigated with the treated effluent water under TEWLIS scheme. The main crops cultivated in the ayacut area are coconut, su garcane, sunflower, groundnut, tapioca, etc. The lands which were once dry and parched are now lush green and a perennial source of revenue to the land owners. 159 acres of land in abutting villages are covered under Captive Plantation to grow eucalyptus trees through drip irrigation using treated effluent water. TNPL was awarded the prestigious TERI Corporate Environmental Award 2008 for the efforts towards environmental management and innovative initiatives among corporates with a turnover of over Rs.500 Crore. To harness wind energy, TNPL set up a 15 MW windfarm power project at Devarkulam and Perungudi which are backward villages of Tirunelveli District. The initial installed capacity of 15 MW has since been enhanced to 35.5MWin five phases.
ENV I R O N MEN T
POLICY O F
Produce eco-friendly quality papers adopting innovative technologies . Provide a cleaner environment by sustained R&D efforts and continued process improvements. Comply with all relevant environmental legislation and regulation . Conserve and optimise the usage of resources viz., pow er, water, fossil fuels and raw materials like bagasse and wood . Impart training to promote and motivate our human resources to be environmentally responsive.
ENV I R O N MEN T
TN PL
P R O TE C TIO N MET HOD S
By using bagasse as the primary raw material instead of wood, TNPL is saving deforestation of about 30000 acres of forest land every year. Due to the usage of bagasse, the chemical consumption in the pulp bleaching process is lower . TNPL·s effluents completely comply with the norms set by Tamil Nadu Pollution Control Board. TNPL is adopting state -of-the-art activated sludge treatment system. Further the treated effluent water is being used to irrigate 1500 acres of land abutting the factory.
The farmers are cultivating cash crops such as sugarcane, groundnut etc using TNPL effluent water. By this process A full Cycle is completed as depicted below: D
THE FULL
CYCL E
D
The company has never used wood from natural f orests. Wood is being sourced only from Farm f orestry. Engaged the services of T amil Nadu Agricultural University (T NAU) Coimbatore f or continuous monitoring of land irrigated with T NPL eff luent water. Water consumption per tonne of paper has been brought down from 124 KL in 1999-2000 to 105 KL in 2002-03. uring the year 2003-04 this has been further reduced to 83 KL. 80 of the water drawn from the river is being supplied back f or irrigation as treated eff luent water. T NPL has installed Rainwater Harvesting System with a catchment area of 1500 S .M in its administrative building at Kagithapuram during 2002-03 and an additional 5000 S .M in and around the plant premises during 200304. E
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Plantation of hardwood pulp
Plantation To meet the growing raw material requirement and to sub -serve 1988 National Forest Policy Guidelines of the Government of India, TNPL initiated plantation programmes during the year 2004-05. In a span of 5 years, TNPL has raised plantation in 40291 acres and is committed to raise plantation in about 15000 acres every year to attain the target of 1 lakh acres by the year 2012 -13. The plantation programmes comprise two approaches viz. Farm Forestry and Captive Plantation. About 37557 acres of pulpwood plantations have been raised so far in 8235 farmers· land with assured market tie-up arrangement. Captive plantations are raised in large land holdings of minimum 25 acres in a single block belonging to the participating farmers either on longterm lease or on revenue sharing basis. About 2734 acres of technology based plantations have been raised under Captive Plantation Scheme over a period of five years. Rational agro forestry systems under the programmes will result in green belt / green cover continuously and thus restore the ecological balance of the operational area. Implementing this programme and achieving the
target of 40,000 ha (100,000 acres) of pulpwood plantation outside the forest area by the year 2012 will definitely convert the underutilized degraded wastelands into green cover. Further, by establishing pulpwood raw material outside the forest area, the same amount of natural forest will be protected without disturbance by the people for pulpwood and firewood. The programmes provide gainful income to farmers from the underutilized lands by which the standard of living and social status of the rural farmers will be improved. The programmes will also provide substantial employment in a sustaine d manner by which the landless labour and poor people will get regular income and improve their living conditions. The programmes will generate assured income to the landowner / farmer from sale of pulpwood, firewood and intercropping.
Process Description
Process Description:
1.Bagasse Handling Plant: The plant is designed to handle 3600 tonnes per day of Mill wet bagasse at 50% moisture. Bagasse received in lorries is unloaded in hydraulically operated tippling system and passed through Depithers to separate Pith and Fibre. The pith is sent to the Boilers to be used as fuel and Depithed bagasse is stored in the yard through Boom Stackers. In the Boom-stacker water is mixed with bagasse to remove the water solubles. The yard has a capacity to store 6 lakhs tonnes of bagase. The bagasse from the storage yard is reclaimed through Dozer -Loader-conveyor system to reclaim chest. It is then washed and processed for Chemical Bagasse pulping and Mechanical Bagasse Pulping. The pith is being separated through side hill screens and sent to pith press for filtering the water and the same is sent to Power Boilers through conveyors for burning as fuel. 2.Pulp
Mill The Pulp Mill consists of Hard wood pulping (HWP), Chemical Bagasse Pulping(CBP) and Mechanical Bagasse pulping. The company has a facility to lap 50 bdmt per day of surplus pulp at 60% moisture for future use and sale. a)
Hardwood
pulping: The Eucalyptus and other tropical Hardwood logs are drawn from wood yard chipped and chips are screened and stored in the silo. The chips are fed from Silo to Super Batch System (Digester) through a conveyor and cooked with white liquor. Pulp from the digester area is sent to the brown stock area. The pulp is screened to remove impurities and washed in several stages to remove cooking chemicals and dissolved.
The pulp is further delignified in the OxyTrac system (two -step oxygen delignification stage) and washed in a post oxygen washing stage prior to entering the bleaching area. The pulp is b leached in the ECF ² Bleach plant and stored in the towers wherefrom it is supplied to paper machines. b) Chemical Bagasse pulping: The washed bagasse is fed, to twin tube continuous digesters wherein it is cooked. After cooking, the pulp is blown to a common blow tank continuously.
The cooked bagasse pulp from the blow tank is washed in a t hree stage counter current rotary vacuum filters and stored in high density storage chest. The pulp is then cleaned in a battery of centricleaners and thickened. The thickened unbleached pulp from the pulp streets will be collected in a common LC tank and fed to a new 500 odt/d Elemental Chlorine Free bleaching (ECF) plant for bleaching. Bleached pulp is then stored towers wherefrom it is supplied to Paper machines. c) Mechanical Bagasse Pulping: The washed bagasse is passed through steam tubes mixed with cooking chemicals to Thermo Mechanical Pulp (TMP) refiners where it is defibrated and refined and stored in blow tank. The pulp from the Blow tank is again refined in an atmospheric Chemi Mechanical Pulp (CMP) refiner with some more addition of chemical. The refined pulp is then screened in Heavy Duty pressure screens, then passed through Centri-Cleaners to remove the fine sand and shives. This screened pulp is bleached with Hydrogen peroxide and soup solution. After a retention of 2 hours in the reaction tower, the pulp is then neutralized with Diluted Sulphuric Acid and stored in a storage tower to be supplied to Paper Machine.
3.Paper Machines Metered quantities of pulp are drawn to a blending chest for the required furnish of paper in the stock preparation plant. The stock preparation consists double disc refiners for post refining hardwood pulp and a control refiner for refining mixed stock before admitting to the paper machine. The pulp is deaerated and then pumped to the head box of the machine after centricleaning, by a pulsation free fan pump through centri screen. The sheet formation takes place on the synthetic wire with large quantum of dewatering. The water is send to the saveall for recovery of fibres and reused in the system.The press zone configuration is a Trinip System where the sheet is further dewatered to 40% consistency by application of hydraulic loads. I
I
The paper sheet passes through a four groups of steam heated dryers to achieve the desired dryness. The paper finally passes through a four roll calendar stack for controlling the surface properties of paper and subsequently reeled onto jumbo rolls. Converting, finishing and packing lines are designed for production of finished paper in reelsor sheets and consists of a Winder for cutting & winding of paper to the sizes required.The mill has installed 2 No. fully automatic ream wrapping machines with a total capacity of 150 tpd, to meet the demands of A4, Folio, A3 size papers.
4.Utilities
a) Steam: The Pulp Mill, Soda Recovery Plant and Paper Machine need Low Pressure (LP) and / or Medium Pressure (MP) steam for process. The required steam is generated using solid fuels like coal, lignite, agro fuels, pith in varying proportion. The steam generated from the service boilers and Recovery Boiler is super heated steam and is converted to High Pressure Steam (HP Steam) by injecting water into process. The HP steam so generated has to be extracted into MP & LP steam by passing through Turbo Generators for use in process. b) Power: The company has five Turbo Generators to meet its power requirements. After meeting the in-house requirements, the balance generated power is sold to TNEB at an agreed price. c) Water: The company has a sanction to draw upto 16 Million Gallons per day (MGD) from River Cauvery. The water is connected from the intake wells to the water treatment plant through underground pipe lines. The water is treated and drawn for use in process, DM plant, soft water plant and colony. d) Bio Methanation Plant: Bio-Methanation Plant for the treatment of bagasse washing effluent has been installed during 2003-04 based on UASB OPITIMA process. The Optima process is based on Upflow Anaerobic Sludge Blanket (UASB) process. In UASB process the organic matter is digested, absorbed and metabolized into bacterial cell mass and in turn to bio-gas by anaerobic micro-organisms.
TNPL Product mix
TNPL Product mix - Printer's delight TNPL manufactures
a range of high-quality surface
sized and non-surface sized papers to suit the requirements of modern high -speed
printing machines. TNPL's state -of-the-art technology supported by a team of dedicated professionals ensure that customers always get quality products. Further, 'Online Process Control Systems' in the manufacturing processes help measure and control the critical parameters online. TNPL Ultra
White Maplitho
The whitest in the range of maplitho paper with a high degree of opa city. Has the necessary ingredients to suitvhigh -end multi-colour printing. Best suited for making premium quality diaries, calendars, Annual Reports and general multi colour printing. TNPL Elegant
Printing
A popular choice of printing houses. With a combination of high brightness and excellent surface finish, it is best suited for diaries, calendars, posters, Annual Reports and quality text books. An ideal paper for varnishing. TNPL Hi- Tech
Maplitho An economical paper offering a combination of high brightness,
strength and stiffness, with improved optical prope rties. Suited for quality multicolour printing and high speed web offset printing.
TNPL Superprinting
Maplitho
A product for high speed printing. The smooth surface with an excellent finish gives unique print evenness. This printer friendly product exhibits high degree of runnability and low degree of ink consumption. This new product from TNPL is becoming an ideal choice among print ers and publishers. TNPL Radiant
Printing
Non-surface sized paper offering good strength and brightness. This paper is best suited for commercial grade printing, as also for textbooks and brochures. Best suited for Student exercise notebooks. TNPL
Offset Printing
This bright paper has excellent internal bonding strength and is ideal for high speed commercial offset printing and for continuous computer stationery. Also suited for Student exercise notebooks. TNPL
CreamWove
A traditional product by its name with the TNPL stamp of quality. Formulated to offer complete satisfaction to the customers. It is ideal for examination paper, general writing and text books
TNPL branded products
TNPL branded products Copy Crown
A high opacity, multifunctional, super bright paper aimed at the Office segment, designed to meet all the day-to-day needs of a modern business. This cut sized, packaged paper is marketed in attractive and compact 500 sheet packs of A4 size 80 GSM. Copy Crown is best suited for Laser, Inkjet, Plain Paper Fax printing and Digital copying for sharp contrast and image clarity TNPL Copier
This is a international standard copier paper has quickly caught the minds of the customers in a discerning market. The 80 GSM and 75 GSM grades come in A4, A3 and Legal sizes. The uniqueness of TNPL Copier is its ability to give clear and hi -speed copies. Excellent dimensional stability and curl resistance capabilities ensure ´absolute copying freedomµ.
Eezee Write
TNPL's ready-to-use, packaged writing paper. Marketed in Academy and Double Foolscap sizes, cut packed in protective packs. Its bright, smooth surface is excellent for writing. Eco-Friendly Exercise Notebooks
Premium quality soft-bound notebooks popular among students for the attractive and trendy designs, durable binding and smoothness in writing. These rightlypriced notebooks come in popular sizes to match student needs. TNPL Commander A new A4 cut-size economy paper with improved sheet properties for multipurpose office application. Packed with high brightness coupled with enhanced visual efficiency. Uniquely designed for high speedhigh volume photocopying and for common desktop printers .
>>>>>>>>>>>Marketing
Marketing
The Indian Paper Industry ranks 15th among the global producers. The Industry is fragmented with over 600 units with capacity ranging from 3 to 700 TPD based on virgin pulp, agro waste and recycled fibre. This has resulted in a very heterogeneous and competitive market. In an industry facing acute raw material scarcity, high energy demands and changing customer requirements for quality, TNPL enjoys 10% share in the Indian printing and writing paper market. Marketing in TNPL has always been a ´gatewayµ function. The company has achieved ´ Zero Stockµ during the past 17 years in a row. This was possible through efficient ´Production-Customer-Despatchµ chain management. The company has developed an effective in -house mechanism for order processing, production planning, storage and material de spatch. As the largest exporter of printing and writing of paper in the country, the company exports to various nukes and corners of the world.
TNPL'S EXPORT PERFORMANCE
In recognition of its export performance, the Organization has bagged the ´Special Export Awardµ from CAPEXIL for the 9th consecutive year. The company continues to focus on export of printing and writing paper as a corporate philosophy. TNPL has established a wide sales network consisting of 54 domestic dealers and 7 sales agents in overseas market. TNPL maintains countrywide branches in 9 major cities. The Marketing function encompasses one of the most modern comprehensive information management systems which provide real time customer and market analysis. The company is equipped with state of the art storage and shipping systems for fast and efficient despatch.
State of the art storage and shipping sys tems help fast and efficient despatch.
Apart from the above, TNPL is also exporting about 18% of the PWP production to 20 countries around the World . THE EXPO RT NETWO RK 1.
11. Philippines
Australia 12. Singapore 2.
Egypt 13. Sri
Lanka
3. Greece
14. Sudan
4.
15.SouthAfrica
Indonesia 16. Taiwan
5. Jordan 6. Kenya
17. Turkey 18. U.A.E 19. U.K
7. Malaysia
20.
Yeman
8. Myanmar 9. Nepal 10 Nigeria
TNPL is having marketing offices at the major cities of the Country to regulate the marketing activities. Regular customer meets are arranged for continuous customer feed back and corrective action. During 2004-05 the company has sold 7708 tonnes of Newsprint and 193532 tonnes of Printing & Writing Paper. Of this, 41264 tonnes of Printing & Writing Paper was exported valuing Rs 127.68 crores. The exports recorded a growth of 37% in quantitative terms and 47% in value terms during the year 2004 -05 compared the pervious year. Thus TNPL recorded new peak in Exports during 2004-05. Symbolic of TNPL·s commitment to the environment, the World Wide Fund for nature (WWF) has entered into a pact with TNPL to use the ¶Panda· logo in TNPL·s branded products.
Tnpl Quality Control Policy
Tnpl Quality Control Policy ´ TNPL is commited to manufacture and supply eco -friendly papers to customers satisfaction with emphasis on continual improvements in its quality managent systemµ.
TNPL has been consistently recording increase in exports year by year, which demonstrates the company·s commitement to Quality. Direct interaction with the ultimate customers through customer serice has helps the company Customer Satisfaction Index (CSI) ranging from 7.01 to 7.50. Customized products are also being manufactu red by TNPL to meet the customer delight. The Online Integrated Information System (OIIS) a mini ERP package developed by CMC Ltd for TNPL integrates the flow of information from all the sections of the company covering production, materials, finance, marketing etc. This OIIS has greatly improved information transfer for faster and timely decision making for assured product quality. The automated process control facilities ensure complaint free products at various stages up to the fi nal packing and despatch. TNPL·s in-house Research and Development facility is recognised by the Department of Scientific and Industrial Research (DSIR) New Delhi. The R&D department has sophisticated state -of-the art instruments and equipments.
Distribution of shares
Distribution of shares In the year 1997 nearly 500,00,000 No. of equity shares allotted to promoters i.e. Government of Tamil Nadu. During November 1995, the Company issued 200,00,000 No. of equity shares of Rs 10 each at a prem. of Rs 100 per share through a prospectus. Of which the following were reserved for allotment on a preferential basis: (i)
3,30,000 shares to Indian working directors, workers of
the Company (only 2,76,500 shares taken up). (ii) 21,70,000 shares to NRIs (all were taken up). (ii) Remaining 175,00,000 shares issued to the public alon with 53,500 shares not taken up by employees.
FinancialHighlights:-
FinancialHighlights:-
STRATEGY
STRATEGY
In a market driven economy where the price is determined in a competitive environment by market forces only low cost high quality products can sustain in the long run. Taking this into account, TNPL is focusing its strategy to impart to it the ability to meet the adverse conditions and be a producer of quality products at competitive rates. The strategies adopted in this regard are: 1. Sustainable growth 2. Efficient cost management 3. Financial re-engineering, 4. Customer centric approach 5. Innovation 6. Optimum utilization of Human resources Sustainable Growth:
TNPL has grown from an initial capacity of 90000 Mts per annum in 1985 to 245000 Mts per annum as of date in stages. Under the Mill Development Plan completed during May 2008, the pulp production c apacity has been increased from 520 tpd to 720 tpd. The bleaching sequence has been changed from conventional bleaching to Elemental Chlorine Free bleaching. The Life Cycle Extension of Paper Machine-I has been implemented. The new Paper Machine will become operational from June 2010. Every phase of growth is supported by latest technology and installation of the state-of-the-art machineries. The Company has also planned to replace three old boilers installed during 1984 with a new single boiler and install a new TG of a capacity of 40 MW in replacement of two old TGs. The above replacement would make the Company productive on energy front. These two projects would be taken for implementation during the current year.
Efficient
Cost Management
TNPL has implemented several cost reduction measures to keep the cost of production low. Hard wood pulp production was increased from 42357 Mts. in 2007-08 to 84854 MTs. in 2008-09. This is the 9th year in which the Hardwood Pulp production has been raised in a row. Change over from Acid Sizing to Alkaline sizing has improved the machine runnability and reduced the finishing loss besides achieving savings in chemical consump tion.
TNPL has benchmarked its operation at the micro level. This has ensured the optimum utilization of resources. Separate Business Unit Concept (SBUC) is being effectively practised for evaluation of performance of various cost and service centers withi n the Organisation. The combination of these two tools - benchmarking and SBU concept - has facilitated the company to improve the overall profitability. TNPL is self -sufficient in power. Surplus power is exported to the grid. Besides, the Company has also taken several cost cutting measures resulting in one time and recurring savings. P
P
Financial
re-engineering
Swapping the multi-currency world bank loan of USD 45 million into US Dollar denominated FCNR(B) loan and reducing the loan repayment period from 10 years to 5 years had resulted in a saving of Rs.39.95 crore to the Company upto 7th December 2007, the last date of payment of the entire loan. The company is also availing short term loans at highly competitive rates to keep the interest rates low. The financial closure for the Mill Expansion Plan for availing term loan of Rs.666 Crore has been done. TNPL will be availing ECA credit of Euro 60 Million as part of the MEP loan at a highly competitive interest rate. All Foreign Currency loans are hedged for currency risk on the date of availing of loan.The average cost of the long term loan availed as on 31.3.2009 works out to 8.17%.
Customer Centric
Approach
TNPL keeps the product mix in line with the market demand. Copier produ ction has been increased from 19311 Mts. in 2002 -03 to 55504 Mts. in 2008 -09 registering a compounded average growth of 19% . The elegant printing has become a star product in both the domestic and the export market. Elegant printing production was increased from 31926 Mts. in 2006-07 to 34160 Mts. in 2008-09. TNPL has exported 33461 Mts. of uncoated Printing & Writing Paper during the year 2008-09. TNPL has introduced superprint maplitho paper during the year. This has become a printer's choice with considerable flow of orders. TNPL also introduced 50 gsm papers during the year. An optimum mix of market sales, direct sales and exports has enabled the company to obtain the best value for its products. TNPL has framed a Customer Care Policy . TNPL would be introducing 47 gsm papers in creamwove and radiant paper and 70 gsm copier paper during the current year. P
Innovation:
P
The bio-methanation plant commissioned during the year 2003 -04 for generating methane gas from bagasse wash water has ge nerated 278.39 lakh m3 of methane gas till 31.3.2009. The methane gas used in lime kiln in replacement of furnace oil facilitated a savings of Rs.30.39 Crore upto 31.3.2009. The project has been registered with UNFCCC as the country's first CDM Project in the waste management sector. Two phases of Wind Farm with a total capacity of 6.75 MW have been registered with UNFCCC and 11233 CERs valuing Rs.1.00 crore have been obtained during July 2007 to June 2008. TNPL has installed shoe press in both the paper machines and a pre-metered size press in PM I. TNPL is in the process of installing a 400 tpd cement plant for converting the mill generated lime sludge and fly as h generated into high grade cement.
SUCCESS DRIVERS
Environment Management Environment performance improvement has also been an area of focus of the R&D and studies were undertaken to improve the quality of effluent. Decolorisation studies of final effluent and other colored streams with Ozone were undertaken in laboratory scale and on continuous pilot plant scale. The results were encouraging and a plant scale Ozone decolorisation programme has been drawn up. Compliance to pollution control norms and CREP regulations has been strictly adhered to. Bagasse Management TNPL requires around 11.6 lakh tonnes of wetwhole bagasse for producing 2,45,000 Mts of Newsprint and Printing & Writing Paper. To ensure that adequate quantity of bagasse is generated, TNPL has entered into firm tie -up arrangements with seven sugar mills for procuring bagasse on substitution basis. The depithed bagasse stock as on 31st March 2009 was 356942 Mts. eq uivalent to 509917 Mts. of wetwhole bagasse. No bagasse shortage is anticipated during 2009 -10. Depending on the requirement, additional tie -up arrangements would be made at appropriate time. Fuel Management TNPL uses solid fuel for generation of steam and power. Besides solid fuel, TNPL uses agro fuel such as saw dust, paddy husk, coir pith and coconut shells, both in the main factory and the sugar mills. TNPL uses a judicious mix of imported coal, indigenous coal, lignite and agro fuel depending on the av ailability and economics. Water Management TNPL sources water from river Cauvery. TNPL has optimized the water consumption. TNPL has also installed series of rain water harvesting structures in the factory and colony premises. The Mill Development Plan imp lemented in May 2008 has reduced the fresh water consumption to a considerable extent. The fresh water consumption has been reduced to 62 Kl per tonne of paper production post stabilization of MDP. Continuous action is taken to further reduce the water consumption. The reduction in water consumption has brought down the treated effluent discharge considerably. Energy Management TNPL has five turbo generators with a power generation capacity of 81.12 MW including one new TG of 20 MW added under the Mill Deve lopment Plan during the year 2007-08. Power required for process requirement is met from the captive power generation. Surplus power is exported to the State grid. However, with the increase in imported coal price, the power export to the State grid has be come uneconomical. Hence, TNPL has suspended export of TG power since September 2007 except a small quantity due to operational reasons.
Wind Farm for Green Power TNPL installed its first Wind Farm of 15 MW capacity during 1993 -94 at Devarkulam and Perungudi in Tirunelveli District. Since then, TNPL has increased the Wind Farm capacity to 35.50 MW in stages. The wind power is exported to the State grid. Two phases of Wind Farm with a total capacity of 6.75 MW have been registered with UNFCCC and 11233 CERs valuing Rs.1.00 crore have been obtained during July 2007 to June 2008. The project has generated 55905 CERS upto 30.06.08. 11500 CERS are likely to be received for the period from July 2008 to June 2009. Steps are being taken to register Phase IV & Phase V expansion of wind farm of total capacity of 13.75 MW with UNFCCC. The methane gas generated in Bio Methanation plant is used in lime kilns in replacement of furnace oil.
Research and
Q
evelopment
The R D has been working towards making world class paper with bagasse pulp in various grades, f ocussing on the eco friendliness of the product.The R D has been recogni ed by the Department of Scientif ic and Industrial Research (DSIR) New Delhi. R
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L ot of work is being done towards improvement in the raw material sources. Accordingly, in the biotechnology division, screening of 37 improved clones from the Institute of f orest genetics and tree breeding were completed as part of ongoing research to identify suitable eucalyptus clones based on f ibre and pulp quality. The biotech division has developed micro propagation technique f or other pulp wood species like Casuarina and Melia and is currently engaged in identif ication of suitable genetic materials f or pulp wood breeding work. Excellence in Corporate Governance The Institute of Company Secretaries of India(ICSI), New Delhi, has conferred on T NPL, the "ICSI National Award f or Excellence in Corporate Governance" f or the year 2004 in the category of public sector recogni ing the company's application of best management practices, compliance of law in true letter and spirit and adherence to ethical standards f or effective management and distribution of wealth and discharge of social responsibility f or sustainable development of all stakeholders. S
Achievements during 2008-09 Highest production and sale of 254903 MT of paper. Both were higher by 9432 MT over the previous year. Copier production reached 55504 MT registering a growth of 11% over the previous year. Achieved a highest ever turnover of Rs. 1066 Crore. ´Zero Stockµ of finished goods (NP & PWP) at the end of the financial year for the 18th time. Exported 33461 MT of printing and writing paper during the year. Implemented Farm Forestry Scheme in 9362 acres and Captive Plantation Scheme in 1209 acres. Covered 40291 acres of land under the schemes upto 31.3.2009. Produced 70.35 lakhs clonal plants in the Clonal Propagation and Research Centre (CRPC) during the year. Implemented the Mill Development plan in all respects and changed over to ECF bleaching. Two phases of wind farm with a total capacity of 6.75 MW were registered with UNFCCC. The project has generated 55905 CERs upto 30.6.08. Achieved the highest Hardwood Pulp production of 84854 MT against 42357 MT in the previous year. Received the prestigious for the second time. Bagged from the Institute of Cost and Works Accountants of India, Kolkata. Received the from Indian Institute of Materials Management (IIMM), Chennai in recognition of the Company's performance in the area of Inventory Optimisation. ´IPMA Paper Mill of the year Award 2007-08µ ´ICWAI National Award for Excellence in Cost Management - 2008µ ´Supply Chain Performance Excellence Awardµ 3
1990- 2000- 2001- 2002- 2003- 20042000 2001 2002 2003 2004 2005 Revenu e (RS.IN
2005 2006
2006 2007
2007 2008
2008 2009
LAKHS) SALES & OTHER INCOM E
5092 5
5817 9
5590 6
5288 5
5829 0
6682 3
