PAPER PAPER MANUFACTURINGMANUFACTURING

Production Management – Production Management – II

Group 3Group 3

AGENDAAGENDA

Overview of Paper IndustryOverview of Paper Industry Industry ClassificationIndustry Classification Paper Manufacturing processPaper Manufacturing process Industry StandardsIndustry Standards Major players in Paper IndustryMajor players in Paper Industry A Tour through a paper manufacturing A Tour through a paper manufacturing

companycompany

PAPER INDUSTRYPAPER INDUSTRY Power and capital intensive industryPower and capital intensive industry Mills are classified as forest based mills, agro Mills are classified as forest based mills, agro

waste/residue based mills and recycled fiber waste/residue based mills and recycled fiber based millsbased mills

Industry broadly classified into paper & Industry broadly classified into paper & paperboards, and newsprintpaperboards, and newsprint

About 515 units all over IndiaAbout 515 units all over India Principal markets - China, Japan, India, Principal markets - China, Japan, India,

Malaysia, Singapore and Thailand Malaysia, Singapore and Thailand India – less than 2 percent of the global demand India – less than 2 percent of the global demand

for paper and paperboard for paper and paperboard

PRODUCT MIX

Jumbled

PR

OC

ES

S P

AT

TE

RN

Jumbled But Dominant

Line Flow

Cont Flow

One off Low Vol High Vol Mass

CONT

PRODUCT PROCESS PRODUCT PROCESS MATRIXMATRIX

Paper MakingPaper Making ProcessProcess

Raw MaterialsRaw Materials

Soft WoodSoft Wood Hard WoodHard Wood GrassesGrasses StrawsStraws Cotton Linters Cotton Linters RagsRags Linen fiberLinen fiber Waste PaperWaste Paper

ChippingChipping

Bamboo or Wood as such cannot be used Bamboo or Wood as such cannot be used for pulping for pulping

Wood logs/bamboo are to be chipped into Wood logs/bamboo are to be chipped into small pieces small pieces

Some wood species cannot be chipped Some wood species cannot be chipped directly and needs debarking directly and needs debarking

Chips of size 5-35 mm are takenChips of size 5-35 mm are taken

PulpingPulping Pulp is obtained by removing impurities Pulp is obtained by removing impurities

from the wood & other raw materials from the wood & other raw materials Two types of PulpingTwo types of Pulping

Mechanical PulpingMechanical Pulping Chemical PulpingChemical Pulping

Sulphate Process "(Alkaline process)“Sulphate Process "(Alkaline process)“ Sulphite Process "(Acid process)“Sulphite Process "(Acid process)“

Mechanical PulpingMechanical Pulping•Grinding logs against a water-lubricated, rotating, stone-faced drum

•The woodchips are pre-softened-TMP

•Investment costs low

•Yield is high

•Suitable for bulk grades of paper

•Pulp retains some lignin.

Chemical pulpingChemical pulping Alkaline kraft or sulphate process, which uses Alkaline kraft or sulphate process, which uses

caustic soda and sodium sulphate. End-uses are caustic soda and sodium sulphate. End-uses are widespread, with bleached pulp particularly used widespread, with bleached pulp particularly used for graphic papers, tissue and carton board, for graphic papers, tissue and carton board, wrappings, sack and bag papers, envelopes and wrappings, sack and bag papers, envelopes and other unbleached speciality papers.other unbleached speciality papers.   

Sulphite: Uses bisulphite liquor. End-uses range Sulphite: Uses bisulphite liquor. End-uses range from newsprint, printing and writing papers, from newsprint, printing and writing papers, tissue and sanitary papers. Sulphite can be either tissue and sanitary papers. Sulphite can be either bleached or unbleached bleached or unbleached

Cooked pulp is then washed and screened to Cooked pulp is then washed and screened to achieve uniform quality achieve uniform quality

The cooking chemicals are recovered through The cooking chemicals are recovered through evaporation and reusedevaporation and reused..

Chemical vs MechanicalChemical vs Mechanical

Chemical ProcessChemical Process Energy consumption-Energy consumption-

LowLow Yield from wood-45%Yield from wood-45% Long fibresLong fibres Paper strength- HighPaper strength- High Production Cost- Production Cost-

HighHigh

Mechanical ProcessMechanical Process Energy consumption-Energy consumption-

HighHigh Yield from wood-95%Yield from wood-95% Fibres brokenFibres broken Paper strength- LowPaper strength- Low Production Cost- LowProduction Cost- Low

BleachingBleaching Pulp too dark to use.Pulp too dark to use. Bleached using chlorine, chlorine-dioxide Bleached using chlorine, chlorine-dioxide

and chlorine peroxide.and chlorine peroxide. Fibres are still stiff. Broken down by Fibres are still stiff. Broken down by

beating down using a series of serated beating down using a series of serated metal discs.metal discs.

Forming the sheetForming the sheet Rinsed and diluted with water and fillers Rinsed and diluted with water and fillers

such as clay and talc added.such as clay and talc added. 99% water.99% water. Pumped into headbox.Pumped into headbox. The pulp is passed through a rapidly The pulp is passed through a rapidly

moving wire mesh and gradually the moving wire mesh and gradually the water drains away.water drains away.

Passed on to the press section.Passed on to the press section. A dandy roller near the end helps to A dandy roller near the end helps to

smooth out the paper. The dandy roller smooth out the paper. The dandy roller improves the formation of the paper web improves the formation of the paper web by application of pressure by application of pressure

Coating, drying and Coating, drying and CalenderingCalendering

The calendars are series of polished iron The calendars are series of polished iron rollers stacked one on top of the other, rollers stacked one on top of the other, through which the finished paper will pass through which the finished paper will pass to smoothen downto smoothen down

The paper may be coated with pigments, The paper may be coated with pigments, latex to give it a higher gloss or to impart latex to give it a higher gloss or to impart some other desirable characteristic. some other desirable characteristic.

Finally, the sheet is collected on a take-Finally, the sheet is collected on a take-up roll and removed from the paper up roll and removed from the paper machine.machine.

Cutting and PackagingCutting and Packaging

The new paper roll is simply rewound on The new paper roll is simply rewound on a new core, inspected, and shipped a new core, inspected, and shipped directly to the customer.directly to the customer.

Other paper grades, however, may be Other paper grades, however, may be further smoothed by passing them further smoothed by passing them through a "supercalender" or they may through a "supercalender" or they may be embossed with a decorative pattern.be embossed with a decorative pattern.

The paper may also be cut into sheets at The paper may also be cut into sheets at the mill, ready boxed and wrapped for the mill, ready boxed and wrapped for shipping. shipping.

Paper RecyclingPaper Recycling

Paper can be recycled only 5 to 8 times Paper can be recycled only 5 to 8 times before the fibers in the paper become too before the fibers in the paper become too short and weak to be reused short and weak to be reused

Paper is Re-pulped and deinkedPaper is Re-pulped and deinked From this point, the pulp is treated just the From this point, the pulp is treated just the

same as if it had been freshly made from same as if it had been freshly made from wood chips rather than recycled wood chips rather than recycled

Major Industry playersMajor Industry players

Ballarpur Industries Ltd. Ballarpur Industries Ltd. Tamil Nadu Newsprint & Papers Ltd Tamil Nadu Newsprint & Papers Ltd Hindustan Paper Corpn. Ltd. Hindustan Paper Corpn. Ltd. J K Paper Ltd. J K Paper Ltd. West Coast Paper Mills Ltd. West Coast Paper Mills Ltd. Seshasayee Paper & Boards Ltd. Seshasayee Paper & Boards Ltd. I T C Bhadrachalam Paperboards Ltd. I T C Bhadrachalam Paperboards Ltd. Rama Newsprint & Papers Ltd. Rama Newsprint & Papers Ltd. Hindustan Newsprint Ltd.Hindustan Newsprint Ltd.1717

Industry StandardsIndustry StandardsIS 1060 : Part 1 : IS 1060 : Part 1 :

1966 1966 Methods of sampling and test for paper and allied products: Part 1Methods of sampling and test for paper and allied products: Part 1

IS 1060 : Part 2 : IS 1060 : Part 2 : 1960 1960 Methods of sampling and test for paper and allied products: Part 2Methods of sampling and test for paper and allied products: Part 2

IS 1060 : Part 3 : IS 1060 : Part 3 : 1969 1969 Methods of sampling and test for paper and allied products: Part 3Methods of sampling and test for paper and allied products: Part 3

IS 1064 : 1980 IS 1064 : 1980 Specification for Paper Standard SizesSpecification for Paper Standard Sizes

IS 1397 : 1990 IS 1397 : 1990 Kraft Paper - SpecificationKraft Paper - Specification

IS 4006 : Part 2 : IS 4006 : Part 2 : 1985 1985

Methods of test for paper and pulp based packaging materials : Methods of test for paper and pulp based packaging materials : Part IIPart II

IS 4006 : Part 3 : IS 4006 : Part 3 : 1985 1985

Methods of test for paper and pulp based packaging materials: Methods of test for paper and pulp based packaging materials: Part IIIPart III

IS 1763 : 1961 IS 1763 : 1961 Specification for Substances of Paper and Pulp BoardSpecification for Substances of Paper and Pulp Board

IS 2724 : 1964 IS 2724 : 1964 Quality tolerances for water for pulp and paper industryQuality tolerances for water for pulp and paper industry

IS 1848 : 1991 IS 1848 : 1991 Writing and printing paperWriting and printing paper

A Tour Through the A Tour Through the IndustryIndustry

ReferencesReferences http://www.biltpaper.comhttp://www.biltpaper.com http://www.khoj.com/Business_and_Economy/Companies/http://www.khoj.com/Business_and_Economy/Companies/

Paper_and_Packaging/index20.htmlPaper_and_Packaging/index20.html http://www.straightdope.com/mailbag/mpapermaking.htmlhttp://www.straightdope.com/mailbag/mpapermaking.html http://en.wikipedia.org/wiki/Paperhttp://en.wikipedia.org/wiki/Paper http://www.astm.org/Standards/D1968.htmhttp://www.astm.org/Standards/D1968.htm http://bis.org.inhttp://bis.org.in