New capacities in Indian paper industry, and scenario of demand, expansion and technology

New capacities in Indian paper industry, and scenario of demand, expansion and technology

The below article is by Mr N. Srinivasan, Technical Director (Projects), C2C Consultancy, a Indian leader in providing consultancy, engineering, design, Project Management, Erection and Commissioning, and advisory services for pulp and paper industries. Views are personnel 

The Pulp and Paper Times :

Demand:

Despite lot of challenges because of so many factors like COVID, Economic recession because of Ukraine & Russia war in all over the world, raw material shortage India has emerged as the fastest growing market when it comes to growth of consumption increased to 6-7 % and its likely to grown 10-12% as per capita consumption in year of 2023-2030. The per capita paper consumption in India is around 19 kg which is likely to grow to over 28 to 30 kg in the year of 2030 means the production increase will be from current 24 million tons to 40 million tonnes at 2030 and this indicates Indian paper industry to produce at least additional 2 million tons every year to maintain supply and demand gap.

At present market, Segment wise Consumption of paper grades are, Newsprint - 6 % (1.4 million Tons), Writing & Printing / Speciality paper 35%(8.4 million Tons) and Kraft and Packaging paper board  – 59 %(14.16 million tons) and when we are doing estimated calculation for the demand of paper considering year on year growth rate we need additional Manufacturing capacity for Newsprint grade about 120,000 Tons per annum, for Writing & Printing / Speciality paper about 700,000 Tons per annum and Kraft and Packaging paper board about 1,180,000 tons per annum which is very difficult to achieve as there is very few paper mills going for modernize / rebuild / establishing new paper projects to improve productivity and built new capacities which are as follows

• Trident Papers is likely to increase the production capacity from 1,35,000 TPA to 2,10,000 TPA.
• Kuantum Papers aims to extend the production capacity of 25% and introducing new Tissue paper machine of 100 TPD.
• Andra Pradesh Paper limited – is rebuilt & setting up new 2,38,000 MTPA (Approx) paper and board by investing Rs.2000 plus crores.
• Emami paper Mills rebuilt a new Metering size press by Valmet 
• Seshasayee Paper & Boards took over Servalakshmi paper capacity of 75000 TPA of Writing & Printing paper.
• Ruchira paper – New Writing and Printing with the capacity of 100000 TPA.
• JK Paper expand its paper capacity from 2,00,000 TPA to 4,00,000 TPA by investing 1500 Crores.
• N.R. Agarwal Industries setting up new 900 TPD to achieve highest FBB & WLC Quality. 
• Amrit papers set up a new premium quality Kraft of 350 TPD capacity by investing 170 Crores.
• Genus Paper and Boards – Unit 2 likely to increase manufacturing facility by 825 TPD OF Kraft paper and Duplex board.
• ITC - expand its paper capacity from 2,00,000 TPA to 225,000 TPA by Valmet
• TNPL planning to introduce new 100 TPD Tissue machine by investing 300 Crores.
• There are many mills comes up in Kraft paper segment with minimum capacity of 300-500 TPD

Technology Information:

Although the Indian paper  industry is constantly developing, with new technologies to improve the efficiency and sustainability of paper production, there is a challenge to optimize operating parameters as per International standard and to achieve the required performance to increase the overall output with less energy consumption for which Indian paper industry needs to introduce new equipment to compete with international market 

• Introducing of Hydraulic with Auto Dilution Control to Maintain uniform CD profile and 2 Sigma Value to achieve most critical quality measurements for paper and board grades to avoid uneven paper draws throughout the papermaking and converting process.
• Introducing of Smart Cleaning system for wire and press with the pressure of 40-150 bar and with 600 bar for dryer screen cleaning which will reduce consumption of fresh water drastically with better cleaning efficiency, improving the runnability. CAPEX will be affordable and return of investment will be fast.
• Introducing of Turbo blower for Vacuum system to zero down water consumption &to reduce power consumption up to 40% in vacuum system. CAPEX may be high but it will be attractive in long term.
• Introducing of Shoe press significantly improves dryness in press section, reducing the steam consumption by 5-6%, Production increase 15-20 % and better runnability due to less breaks, High Bulk and strength properties. CAPEX will be high but ROI will be within 2 years.
• A Perforated flat box in the press area to improve increase dewatering, better runnability, better profile, Lower friction – lower press drive load, longer felt lifetime.
• Introducing of Condition monitoring system for all the rotating Equipment for minimum down time and Scheduled Maintenance so that machine efficiency will improve like anything. CAPEX will be affordable and return of investment will be fast.
• Introducing Online dryer cleaning system with the pressure of 200 - 600 bar to remove the stickies and improve the machine runnability, reducing the steam consumption and to maintain even moisture profile.
• Introducing of Film Size press to apply sizing solution simultaneously on both surface of paper, Easy operation, quick change of coating weight and better runnability in High speed machine.
• Introducing Air turn unit is to increasing machine speed potentially, reduce contamination, reduce web breaks due to tension fluctuations, Web spreading effect.
• Introducing of Automized Dryer management system for Steam & Condensate and Hood & Pocket ventilation system for trouble free operation even with low skilled operators. 
• Introducing of Advance Reel handling system with fully automized for speed up the packing as well as reduce the Man power.
• Introducing of IQ Dryness Measurement to monitoring Moisture/ Consistency to ensure good quality especially in process changes.
• Introducing Ropeless threading system which will help easy tail pass the paper.
• Introducing Deculator for high-speed machine to improve consistency stability in stock entering the headbox, reduce pinholes and spots leads to increase in strength properties, improve drainage & Formation by reducing Air content and ultimately increase production and machine efficiency.
• Introducing Automized reactor in ETP for High COD, BOD removal efficiency which help to get rid of foul smell, bad odour particularly in packaging paper which goes for food grade packing.

Thus in view of the Current state of Indian Paper Industry and evaluating the condition of future Indian Paper Industry, we have to plan higher mill efficiency with less energy consumption as well as to optimize operating parameters as per International standard, The Indian paper Industry to recognize all the merits / CAPEX / ROI to introduce necessary updated new technology in running mill and establishing new projects.
 

Web Title: New capacities in Indian paper industry, and scenario of demand, expansion and technology