GVG PAPER MILLS LTD

OBJECTIVES OF THE STUDY

y To know about the various departments in a paper mill.

y To know the function of paper manufacturing process.

y To know about various types of paper and their uses.

y To study about the factory environment.

INTRODUCTION

INTRODUCTION TO PAPER:-

The word paper, which is obtained from the Greek word ³PAPYRUS´, originated in china. Paper is an important material tool to plan and execute any work in the world. Now a days schools, collages, business organization come into existence in earn for paper marked to reach the decline stage.

HISTORY OF PAPER:-

Paper gets its name from ³papyrus´, a read that the ancient Egyptians used for making a writing material, they cut papyrus stalks into the steps and pressed crises crossed layers of strips into sheets.

Chilean invented paper in china in 105AD. he uses the inner barks of the mulberry tree for fiber, later the Chinese found that paper making material could be obtained by pounding rags, he mp rope, and old finishing nets to a pulp.

The paper industry was established in Baghdad around 795A.D. French man named NICHOLOUS LOUIS ROBERT invented a machine to make paper as continuous roll rather than sheets.

PAPER INDUSTRY IN INDIA:

Paper industry in India is the 15th largest paper industry in the world. It provides employment to nearly 1.5 million people and contributes Rs 25 billion to the government's kitty. The government regards the paper industry of the 35 high priority industries of the country. Paper industry is primarily dependent upon forest-based raw materials. The first paper mill in India was set up at Sreerampur, West Bengal, in the year 1812. It was based on grasses and jute as raw material. Large scale mechanized technology of papermaking was introduced in India in early 1905. Since then the raw material for the paper industry underwent a number of changes and over a period of time, besides wood and bamboo, other non conventional raw materials have been developed for use in the papermaking. The Indian pulp and paper industry at present is very well developed and established. Now, the paper industry is categorized as forest-based, agro-based and others (waste paper, secondary fibber, bast fibers. In 1951, there were 17 paper mills, and today there are about 515 units engaged in the manufacture of paper and paperboards and newsprint in as one

India. The pulp & paper industries in India have been categorized into large scale and small-scale. Those paper industries, which have capacity above 24,000 tonnes per annum, are designated as large -scale paper industries. India is self-sufficient in manufacture of most varieties of paper and paperboards. Import is confined only to certain specialty papers. T o meet part of its raw material needs the industry has to rely on imported wood pulp and waste paper. Indian paper industry has been de -licensed under the Industries (Development & Regulation) Act, 1951 with effect from 17th July, 1997. The interested entrepreneurs are now required to file an Industrial Entrepreneurs' Memorandum (IEM) with the Secretariat for Industrial Assistance (SIA) for setting up a new paper unit or substantial expansion of the existing unit in permissible locations. Foreign Direct Investment (FDI) up to 100% is allowed on automatic route on all activities except those requiring industrial licenses where prior governmental approval is required. Growth of paper i ndustry in India 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. Government has taken several policy measures to remove the bottlenecks of availability of raw materials and infrastructure development. For example, to overcome short supply of raw materials, duty on pulp and waste paper and wood logs/chips has been reduced. The industry has enormous export potentials.

It is only the government that should encourage the companies in the field to go for export with all its policy support. Use of paper is considered as an index of cultural growth. Key social objectives of the Government like eradicating illiteracy. which in turn stimulate industrial growth of the country. Because of paper industry¶s strategic role for the society and also for the overall industrial growth. The paper industry has an important social role to play for the country. thus. making primary education compulsory etc. The paper industry has. publicity etc. So demand for paper would go on increasing in times to come. it is necessary that the paper industry performs well. The new millennium is going to be the millennium of the knowledge. a catalytic role to play not only for the overall growth of the industry but also for the living standards of the people. tax concessions. . are very much related to the paper industry. The paper industry is also contributing towards fulfillments of various requirements of the industry as a whole like information dissemination. availability of capital etc.

which rely on ³unconventional´ raw material such as waste paper and partly agro residues. Industrial Variety ( Craft paper and Duplex Board ) Over 550 players currently populate the industry and the estimated capacity is about 7. Newsprint 2. imports contributed to about 50% of . The present Excise duty on Paper is 12 %. Nevertheless. the first 3500 tones produced by a mill is chargeable only @ 8 % and thereafter it is @ 12 %. Writing and printing. 3. the growth of various segments. Although the other divisions in the Indian paper industry are also fragmented by international standards. The Government of India from time to time has given some benefits to small industries in order to protect them i. 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. industry fragmentation and intensity of competition have been significantly influenced by the Government tariff policy. Over the years. ³Newsprint´ till about 1995.e. technological changes. Fragmentati on is severe in the ³industrial´ (packaging) grades. Generally. the degree of fragmentation is less severe. was the sole preserve of large public sector units and was well protected by high import tariff barriers. tariff rates have protected smaller units utilizing ³unconventional´ raw material. The three main grades of paper manufa ctured in India are :1. investments levels in specific segments. grades manufactured and raw material utilized.Overview of Paper Industry: The Indian paper industry has been historically divided on a three dimensional matrix identified by size.00 million Metric Tones Per Annum (MTPA).

Currently import duty on newsprint is about 5% and domestic manufacture of newsprint is exempted from excise duty. Imports still constitute about 30% of consumption and newsprint contributes about 10% of the total production of paper and paperboards. ³Lower end cultural grades´ manufactured by smaller players using unconventiona l raw materials in low investment. Historically.a. The high investment levels required and limited ³conventional´ fiber resources are the major deterrents to growth in this segment for both existing players as well as new entrants.the domestic consumption. the bulk of the output of ³Cultural´ grades ± comprising of writing. Import tariff levels. have been high. This segment has been consistently taxed at higher rates due to its size and use of ³conventional´ forest based raw material. low tech plants cater to consumers in the price sensitive sub segment of this market. This growth has relied namely on De-inked waste paper as a source of raw material. With relatively smaller number of players and high import tariff protection. Since then. generally perceived to be higher quality. prices of end products. The Indian Paper industry is going through substantial changes. printing. Global demand for paper is expected to grow by about 4% p. This sub segment depends significantly on the tariff differential based on size and raw material for its viability. who use forest based raw material in integrated pulping facilities augmented by imported pulp. office stationery paper and specialty paper has been the preserve of ³large´ producers. The number of players in the newsprint segment is relatively limited and manufactur ing capacities are larger than in the packaging grades segment. This tariff structure for newsprint has seen Indian newsprint price closely mapping international prices. Investment in plant has also been higher. over the next 5 years. although much lower now. new domestic capacity with private investment has been allowed to be created. The domestic demand is expected to grow at about 8% which will result in increase . still continues a significant barrier to imports.

The paper industry has an important social role to play for the country. Key social objectives of the Government like eradicating illiteracy. it is necessary that the paper industry performs well. a catalytic role to play not only for the overall growth of the industry but also for the living standards of the people. So demand for paper would go on increasing in times to come. Despite to the constraints like over crowded market and limitation in procuring the desired quality of waste paper. are very much related to the paper industry. waste paper and news print is likely to increase by at least 15% to 20% in 2005 -06 to keep up with growing demand for paper in the domestic market. In the current year.of demand by 30 Lakh tones approximately over the next 5 years. The import of raw material for paper including pulp. making primary education compulsory etc. publicity etc. selling price has marginally increased and enabled the industry to partially offset the rise in cost of inputs. 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 paper industry has. . The new millennium is going to be the millennium of the knowledge. fuel & labour. there are indicators of a revival in the Indian Paper Industry. Because of paper industry¶s strategic role for the society and also for overall industrial growth. thus. which in turn stimulate industrial growth of the country. The paper industry is also contributing towards fulfillment of various requirements of the industry as a whole like information dissemination. Use of paper is considered as an index of cultural growth.

F. l GVG paper mill ltd got . The exposure to foreign packaging technology and the need t o satisfy the export customers has led to a drastic change in the industrial packing sector. l By making high end paper in south India the company stands to gain a lot in terms of logistics costs when compared to the competition. Due to environmental concerns. The above change has resulted in more aesthetic and cost effective packing solutions. The corrugators have started using high BF. higher GSM paper and exploit the emerging market situations better. textile and export segments. 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. There is a very good potential market developing for such grades of paper in India.. Hence within 2 to 3 years we will be witnessing an explosive growth of packaging in India mainly in food. 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 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. which can produce up to 24 BF only.FUTURE PROSPECTS: The globalisation of Indian economy has lead to a healthy growt h of 6 to 7% industry and that is growth happening in all the sectors. the use of plastics is likely to be banned by the Government of India within a short span of time. 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. Moreover the Per Capita consumption of paper in India is going up with the advent of packaging in the food industry.

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. 3. 2. pressing and drying to form a sheet of paper. 2) The company intends to manufacture the paper by using Twin Wire Technology and also plans to incorporate all latest equipments to have a cost effective production. The arrangement is in such a way that the wet webs come into contact before going to the press. Burst factor. Sri Lanka and eastern African countries is also bright. The twin wire technology employs two wires drawing pulp stock from two separate head boxes. Improves strength properties of paper namely. Tensile strength and Ring crush test values. Tear factor.the advantage of cost benefit while importing raw materials and exporting finished product. . Reduces Cost of Production. Improves formation of paper. l The possibility of exporting substantial quantity of the production to near by countries like. The twin wire technology is superior than the single wire technology due to the following factors: 1. 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. 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.

62 lakh tonnes. 1997. To meet part of its raw material needs.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. Several fiscal incentives have also been provided to the paper industry. The industry is a priority industry for foreign collaboration and foreign equity participation up to 51% receives automatic approval by Reserve Bank of India. There are.f. The country is almost self -sufficient in manufacture of most varieties of paper and paperboards. is confined only to certain specialty papers. at present. . the industry has to rely on imported wood pulp and waste paper. particularly to those mills which are based on non -conventional raw material. 17th July. Import. however.PRODUCTION RAW MATRIAL AND IMPORT: Government has completely de -licensed the paper industry w. about 515 units engaged in the manufacture of paper and paperboards and newsprint in India.e. Foreign investment even up to 100% is approved by FIPB on case to case basis. The entrepreneurs are now required to file an Industrial Entrepreneur Memorandum with the Secretariat for Industrial Assistance for setting up a n ew paper mill or substantial expansion of the existing mill in permissible locations. The production of paper and paper board during the year 2001-02 is 31. The market expectation for the increased production CAPACITY.

Imports of paper and paper products were growing over the years.2 per cent based on wood.3mn people in the country contributing Rs. To bridge the gap due to short supply of raw materials. In 2003-04. Indian paper industry has a 1:1 correlation with the economy. in line with the GDP growth. At present about 60. it has decreased during 2000-2001. The government is planning to target a GDP . The industry has recorded a volume growth of CAGR of 5. particularly small mills. are sick and/or lying closed.47% over the last 3 years.25bn to the Government. The performance of the industry has been constraine d due to high cost of production caused by inadequate availability and high cost of raw materials. it recorded a volume growth of 6%. The capacity utilization of the industry is low at 62% as about 194 paper mills.8 per cent of the total production is based on non wood raw material and 39. Several policy measures have been initiated in recent years to remove the bottlenecks of availability of raw materials and infrastructure development. Demand and Supply gap in Paper Industry: Indian paper industry is the 15th largest in the world and provides employment to 1. Several policy measures have been initiated in recent years. duty on pulp and waste paper and wood logs/chips have been reduced.The proportion of non-wood raw material based paper is increasing over the years. However. power cost and concentration of mills in one particular area. The demand for paper is linked to the GDP Growth.

population growth and the Government¶s allocation for the educational sector. promotional expenditure.26mn tons of paper in 2003 -04. A leading global paper industry consultant projects a shortage of about 0. industrial production. Newsprint capacity in India is estimated at 1. Capacity expansions of over 600. India¶s paper demand is expected to touch 8mn t. domestic production is only 0. With this increase in the GDP growth the paper sector is expected to record a similar growth rate.15mn tons. while consumption of newsprint is 1.supply scenario to keep prices firm The demand for paper is influenced by various macro -economic factors like national economic growth.p.7mn tpa by 2010. the effective capacity is estimated to be lower at 6.1mn tons. but would take 1 -2 years to be operational. Domestic demand for paper is expected to grow at a CAGR of 6-7%.000 tons have been announced by the 7 large players in the sector .59mn tons.12mn tons however.a by 2010. Proposed capacity expansions: Capacity expansions (which cost 50% less than new capacities) have been announced by most players.Growth of about 10% in 2-3 years. The Indian paper industry has an installed capacity of 6.7mn tons while. Favorable demand . The industry produced 5.

PERMISSIONS & TAXES 1. The manufacture of paper through pulp of wood or of other fibrous cellulosic material has been discussed at length. 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 .WTO Impact: WTO as discussed the implication of Indian Paper and Newsprint Industry as part of its negotiations and implications. 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. . How ever. Central Excise: Central Excise is levied @8% for the first 3500 MT production and thereafter @12% on the value of the invoice. In fact the paper industry which are eco friendly imports lot of waste paper into the country in the manufacturing of paper and paper boar d. Generally WTO implication is applicable to all the industries. recovery of waste or scrap for paper and paper board manufacture has been looked at from different angle in the classification of products of Indian Paper Industry. However. in respect of paper industry where waste paper is the raw material and which is eco friendly. GOVERNMENT REGULATIONS. GVG paper mill ltd is into manufacturing of paper out of the waste paper and is an eco friendly project. the impact is not harsh. The Indian Paper Industry has important place in the industrial landscape. The Company is availing permitted Modvat benefits as per Central Excise regulations.

3. A recent notification from Central Government also confirms such a stand. Service Tax: Being classified as a manufacturing industry. Factories Act are obtaine d and duly renewed . VAT (Value Added Tax): VAT replaces the existing multipoint taxes levied by various states with effect from April µ05. As a result. no sorting or segregation is done at source and so most of the waste paper varieties . the paper trade is also covered under VAT for domestic sales done in the state of Kerala. 4. However for interstate sales CST is continued to be levied as per existing Government regulations. As that of other industries.2. Factory Licenses: All the licenses required under Municipality Act. AVAILABILITY OF DOMESTIC WASTE PAPER : Waste paper recovery system in India is very unorganized and unplanned . Bulk of waste paper collected by street collectors in metropolitan cities goes to household paper bag manufacturers. 5. Due to lack of any grading/ classification system in context of waste paper. large quantities of waste paper get diverted for cheaper packaging and other uses or get destroyed as rubbish. the industry even for Job Work on conversion basis will not be subjected to Service Tax requirements. Pollution Control: Necessary permission under effluent discharge Act is obtained and the facilities required to maintain the permission are in place.

Ledger files and papers from Govt. offices. of which only 20% is being made available to paper industry and the rest 60% is usually diverted for other diversified / secondary uses such as wrapping. Industrial refuse Office refuse Corrugated boards. collection of office refuse has not been very high mainly due to unavailability of a viable collection system. 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. The probab le sources of waste paper collection are as under: Waste Source Domestic refuse Paper Examples Newspaper. Universities & large business organizations. Trade refuse Road Sweeping In India. duplex & other packaging board. paper sacks etc. . board cartons. magazines. packing etc. Boards trimmings from converters & packaging manufactures. more than 80% of the paper consumed in India is being collected. In practice. Other fibrous domestic refuse probably find their way as road sweepings.are collected in commingled form.

During the year 1995-96. GVG group has paper mills and 3 textile mills with a combined turnover of Rs. There are 25 wind Mills in our Group of company. This has enabled the company to have a wide range was converted as a dedicated Newaprint making machine which presently produces around 60 MT of Newsprint. In the year 1991.00 Crorers/annnum and imports around Rs.the production was increased to 20 MT per day with the installation of few balancing equipments and increased drying capacity.15.115.the company went in for MG machine to produce Kraft varieties of papar with a capacity of 15 MT per day. The company commenced its production in the year 1986 with a capacity of 10 MT per day and within a span of 5 years.The present capacity of the Mill is 140 MT/Day and the turnover is around Rs.The production capacity of 2 paper mills is 200 MT/Day and the installed capacity of textile mills is 65000 spindles.00 Crores per annum.Thepower Generated .00 Crorers/Annum.00 Crores per annum.The company exports around Rs.12.275.We also have a back pressure Turbine connected to th e FBC Boiler which produces around 24000 units of power per day.the company put up the 3 rd machine(MG) to manufacture special varieties of paper.PROFILE OF THE COMPANY : GVG Paper Mills Private Limited Was Incorporated In the year 1985 as a private limited company with an installed capacity of 3000 MT annum of printing and writing paper. Coimbatore & Kongalnagaram. The company has put up 10 wind mills supplied by various manufacturs in Attukinathupatti Village.

The following are the founder Directors of the company: - 1)Shri M Soundararajan 2)Shri M Velusamy 3)Shri M Amarnath .16.Apart from this.00 Lakhs from our group towards the construction of a modern Electric crematorium in udumalpet .we also do lot of charities for the Temples. Our Group engages itself in lot of social welfare activities and we have recently contributed a sum of Rs.Our group also has a Poly Technique institution in the name of Rudharaveni Muthusamy Poly Techniques which caters to the needs of lot of students in and around our Taluk.from wind mills and Turbine takes care of more than 50% of our power requirement and even during power cut imposed by the Tamilnadu Electricity Board we are able to comfort ably maintain our production without compromising any of our processes.Our Group also sponsors lot of others games which are being conducted in and around Udumalpet. Our Group also contributed for the building of a compound wall of a huge play ground belonging to the Government High School in Udumalpet.

Udumalpet with a fund based limit of 10 crores and non-fund limits of 5.25 Lakhs The company pays an amount of Rs..2..Chandrika etc.The monthly Wage bill workers out to Rs.Rs.Printing & Writing Papers and Kraft varieties of papers in our 3 machine.2.50 Crores by way of Income tax every year and has paid an Advance Tax of Rs. The company has a work force of 250 direct workers and nearly 500 indirect workers in the factory.00 Crores by way of sales Tax and Rs. ..Dinamalar.The following constitute the present Board of Directors of the company. The Newsprint produced by us is being used by most of thr leading dailies in Tamil Nadu like Dinakaran. Manging Directors : Shri M Amarnath Directors : Shri M Velusamy Smt A Padma Shri V Vivek The company has working capital limits with M/S.The New indiaan Express.00 crores per annum by way of excise duty.We are also selling newsprint to major Kerala dailies like Deshahimani.2.2.We have a good network of dealers and consignement agents across the country which helps us in easy clearance of our products.Kaalaikathir etc.5 Crores. We are producing Newsprint.50 crore this year.The Lakshmi Vilas Bank Ltd.

Admin. Tamil Nadu India.com.Pushpathur Village Palani TK.in COMPETITORS:- In a world of competitions. . gvgpmudt@dataone. Madthukulam. They are: 1) Sri Venkatesa papers & board Ltd. 2) Amaravathi paper mills.Udumalpet 642 154 Phone : 04252 -224113. 224513 E-mail : gvgpmudt@gmail. the company has a host of competitors. 3) BVV paper mills.The Factory Address is : GVG paper Mills p Ltd Nallur.Office : GVG paper Mills p Ltd 168/2 Sikkander batcha Street Gandhi Nagar.

Ambarampalayam. raising equity etc. Costing.M. He has made significant contributions in identifying the financial institutions for sourcing the funds for the Mill Development Plan. Ever since he joined Gvg paper mill he has been instrumental in bringing in the financial discipline a nd analysis that helped the Management to take various cost effective decisions. He started his career in 1986 and added to his profile significant skills in the areas of Taxation. Director Finance under assistance of Accounts Manager & Accounts . 5) Seshasayee paper & board ltd.Velusamy. Nilakotai. Insurance. 6) Aliyar paper board. Working Capital Management. Anil Goyal is a Chartered Accountant. Mettupalayam. 7) Karthikeya paper board. Secretarial Services and Financial Management. Costing. Erode. 8) Sudhassan paper mills ltd. has a distinguished career in the area of Corporate Finance and brings with him a unique combination of skills from Accounting. Sathyamangalam. Accounts Department: Accounts Department has also been supervised by Mr. Project funding by way of debt from multinational agencies. DETAILOF DIFFERENT DEPARTMENTS Finance/Administration Department: Mr.4) Dhanalakshmi paper mills ltd.

. Department . Under his supervision and new ideas company has a modern and high-tech accounting software and a well established Purchase Department: Purchase of raw material is supervised by Mr. Customer service. He is the key contributor to the process of developing the Quality Assurance and R&D Functions development in the organization. Director Purchase is assisted by Purchase Manager and Raw Material Quality Managers.Duraisamy. Dispatch Department Dispatch Department has also been supervised by Mr. He is specialized in the areas of Technical Sales.Assistances.Vivek. His contribution in customer customized product development has been and unparalleled.Duraisamy. He is the critical In-house Resource for various Learning Events being conducted in various technical areas. He is assisted by supervisors and dispatch clerks.R. He is assisted by the Production Manager and Plant Supervisors. Later on with his abilities in technical and administrative skills. Director Production. Production Department: Production is supervised by by Mr. took over the role of managing the Production Operations. and Product development.R. computer lab.V. HR. Director Purchase.

Power Measurement offered the right set of capabilities with its energy management software. The compensation package of the Gvg Paper Mill Ltd matches with the Industry Standards with qualities of flexibility. Our work culture that enable its Human Resources enjoy professional freedom. Inherent in them are the qualities like innovation. installed on . and control would optimize mechanical/electrical systems. talent identification and nurturing. Our HR processes stem from the faith in Human Potential and its Creative Power. Our Learning Center is a forum where unique learning events take place as a part of the process of institutionalization of continuous learning. For electrical maintenance GVG Paper Mill Ltd has flexible solution with comprehensive energy consumption logs and immediate access to a range of electrical parameters.GVG paper mill Ltd¶s Human Resource Processes are rooted in business priorities. presenting information remotely via the company's existing computer network. analysis. and avoid unnecessary downtime. GVG Paper Mill Ltd through its 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. pinpoint problem sources. valuing talent and encouraging career growth. continuous learning and improvement in the work processes. manage energy usage. market realities and long term oriented. Maintenance Department: Extensive monitoring. 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.

especially related to fast alarm response. 2. The system proved to be a valuable aid in the design and operation of electrical installations. and the system's modular architecture facilitates affordable growth of all energy management applications. Further operational savings are being re alized. Printing and writing and. Newsprint Gsm = grams per square meter . and a network of intelligent power meters.distributed workstations. PROFILE OF THE PRODUCT: Varieties of the product: The company is producing two types of pap ers 1.

Colour printing. green and yellow. c). 70 and 72 gsm). b).white and colour. g). . Printing and writing papers: a). 61 and 70 gsm). H). 70 and 72 gsm). f).1. e). Manifold(30gsm). d). Economic super colour wave (43.Azure laid (56. 44 and 47 gms).White duplicating [thick] (60. i). Super cream wave (44-58). Colour duplicating (60.cream wave (44-58gsm). Super colour wave (44-47gsm)-blue.

Certificates i). Lining papers . Documents h). Board sheets f). Journals d). Tabloids g). b). Magazines c). Gazette e).2. News print (48 gsm). Newsprint: a).

Head DGM Sales Manager Watchman Shift Supervisor Coop Stores Maistery All Workers All A/c¶s Workers .ORGANISATION CHART: MD GM(operation) Personal officer DGM Technical Purchase Sales All Securit y Time Offic e Canteen Factory Dept.

The various raw materials are.RAW MATERIALS ANALYSIS:- In this section the various raw materials for paper production like wood and bagasse are analysed. CUSTOMER SERVICE: 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 .  LIME  SOAP STONE POWDER  ALUM  DYES  SODIUM SULTHATE  H2O2  SULPHURIC ACID  SODIUM HYDROXIDE  HYDROCLORIC ACID  NITRIC ACID  STARCH.

Bill of the material is also collected by the gate office for their necessary inward material entries. Quick and punctual delivery has added to customer convenience PROCUREMENT OF RAW MATERIALS: Main raw material for the company is corrugated boxes/waste paper which is purchased through local suppliers and global suppliers. Weight of the raw material is tallied with the weighing slip/bill of the supplier. place order for supply of raw material. TESTING/CHECKING OF RAW MATERIAL: After receipt. Director (Purchase) is assisted by team of purchasers. received from the production department. who calls quotations from different suppliers of raw materials. Decision for making purchase is taken by the Executive Director (Purchase) after considering the indents for requirement of raw materials. Company has adopted inventory control system for purchase Raw material. RAW MATERIAL MANAGEMENT: Director (Purchase) after considering lowest quotations along with sample of raw material. it is . If the weight is not tallied with the weighing slip/bill due to shortage. consignment of raw material is weighted at company¶s own weighing bridge. Weight as per company¶s weighing bridge is tallied with the weighing slip as produced by the supplier of raw material.Customer service : We weave the marketing and manufacturing functions together.

A written consent on the back side of bill is taken for information of shortage to supplier. Copy of the report. Lab.6500/Rs. supplier does not accept weight of moisture/prohibited contents he is allowed to take his material back.PMT Rs. . Rates of different type of raw materials are as under :- 1. Copy of the report is then given to supplier of raw material. If. .7000/Rs.8000/. 6. present in the lot of raw material. who tested the percentage of moi sture in the material. sample of same is handed over to laboratory technician. is forwarded to Director (Purchase) for his information and signature purpose. . 3. 5..immediately informed to supplier/driver..5500/Rs. moisture is found in any bundle. 2.. Corrugated Cartoons (Fresh) Corrugated Cartoons (used) Corrugated Cuttings (Fresh) Corrugated Cuttings (Old) Media (Kaccha Material) Media (Core Pipes) Rs. Report is also signed by Lab.6800/Rs.5000/.. 4.. Incharge as well as supplier of material. Technician for moisture and other prohibited contents like plastic strips. . Raw Material Quality Supervisor got unloaded the material in his presence. Vehicle is then allowed to go to raw material godown for unloading with prior intimation to quality checking supervisors. reel core material etc. Report so prepared. is attached with bill of supplier and handed over to gate department for entries in their inward receipt register. If. Weight of moisture/other prohibited contents present in the material is deducted from the total weight of material. . A report is being prepared by Lab. Sample from different bundles of raw material is taken for checking of quality/moisture etc. kaccha material.

Before going to the paper machine. as it. Chemica ls and water.MANUFACTURING PROCESS . The treatment is carried out in appratus called refiner and sizing agents like alum. Paper is manufactured using corrugated cartoons/waste paper. The waste paper can directly be beaten and washed in the beaters for pulping. The main flow of pulp which is freed from tailings in the vibrating screen and fine pulp sieved out from the tailings are put together and sent to the centricleaners which work quite efficiently in removing fine dust. B) PREPARATORY TREATMENT OF STOCK : Pulp. dyes. . is not fit for being converted in to paper and must undergo some preparatory treatment depending on the end product. l oading materials are added in the process to develop its strength. 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. the stock must be prepaid uniformly with a fixed thickness and be screened and refined by crushing so that it may be reduce in to fixed thickness with uniform properties in a uniform speed.

the speed of machine and grammage of paper.Dryer which imparts glaze to the paper. To get M. The wet sheet is pressed dried and smoothened by going through several s ets of roll machines. Paper is finally wound up by means of pop -reel machines. D)FINISHING OF PAPER : Paper and board intended for sale in reels and cut sheets is rewound & cut to certain fixed measurements. Similarly speaking. is then wrapped by plastic cloth and clipped with the help of plastic strips. size and grammag e on each reel for the purpose of identification. Weight as shown on the display is written in .Kraft Paper.G. Supervisor on duty mark a serial number. The rejected produce is returned to pulping section and mixed into the main flow of pulp stocks. the paper making machine performs its function in this way :In the pulp stock which goes over travelling wire the fiber is separated from water & sheets of paper is formed. down to the required consistency with the use of back water generated in the paper making process. Defective paper and board sheets are removed . The out put of a paper machine is determined by the trimmed width of paper. the sheet is then passed through M.G. Wrapped reels are then weighted through electronic weighing scale. is diluted in the mixing box. E) DISPATCHES: Reels so prepared.C) PAPER MAKING : Prior to going in to the paper making machine the stock which has gone through necessary treatments.

In order to get good quality paper. QUALITY CONTROL: The quality control can be defined as checking of the products quality at various stages of production.the reel by the supervisor. Complete record of reels manufactured and reels dispatched are forwarded to account office. . we should control each and every important factor involved in the whole paper making process. Laboratory plays initial role of monitoring the various process variable and enable the concern department to take necessary steps if any thing goes wrong. Reel is then shifted in finished goods godown from where it is dispatched as per orders received. Supervisor also maintained a register in which he entered weight of each reel along with serial number of the reel. Paper making process is a continuous process which involves a lot of operation.

Ujjain Patel Paper Box. Chandigarh Kamal Boxes.P. Daman Meiyappa Paper. Jalandhar Jay Ambe Overseas. Delhi H. Faridabad Lakhani Group of Industries.Cotton Textiles Mills Limited.CLIENTS : GVG keeps stringent control over quality for consistent quality which has helped it have clients like : - a) b) c) d) e) f) g) h) i) j) k) l) Micro Tek. Chennai EMPLOYEES CAPACITY Details of employees are as under :1. 2. Parwanoo Action Shoes. Faridabad Ravi Sons.. Repair & Maintenance Staff Engineering & Manufacturing Staff 15 18 . Udaipur Perfect Pack Ltd. Surat Industrial Packers. Hissar Baldeo Mange Lal.

9. Clerk Supervisors Connected with Process Supervisors Connected with Production Supervisor Connected with Despatches Supervisor Quality Checking Officer Staff Production labours Security 10 5 5 5 5 5 100 5 GVG PAPER MILLS LTD. 5. 7. 4. Stapple Pins & Adhesives) . PROCESS FLOW DIAGRAM Waste Paper Along with 12% Normal Moisture. 8. 6.3.. 9.

G.2 TURBO REWINDER THICKNER REFINER FINISH PRODUCT Solid Waste to Boiler/ETP .DRUM REELER MIXING CHEST NO.CONVEYOR VACCUM BOXES PRESS NO.2 SAND TRAP CENTI CLEANER DRYER DUMPING CHEST FLOW BOX HIGH DENSITY CLEANER MACHINE CHEST M.1 PULPER WIRE PART HEAD BOX PRESS NO.

hot works in fire prone areas. Safety Systems : Safety Work Permit System and Danger Tag System are in use for carrying out repair and maintenance works. The Safety and Accident Prevention activities at GVG paper mill ltd are monitored by a participative safety committee with equal number of members from Management and Workmen. entry in to confined space. There are 3 department level safety sub -committees. 1. Accident Reporting and Investigation : All the accidents and near miss accidents are reported and investigated and reviewed by the Safety Committee. The Safety Department is manned by qualified safety officers and other administrative assistance. The Safety Committee and Sub-committees also inspect the plants regularly. Safety Training : General and need based training is given regularly to all employees including cont.SAFETY & ACCIDENT PREVENTION : 1. Identification of Hazards : Frequent inspections are being carried out by using checklists. The accident data is analyzed and Safety Performance is measured monthly. 3. etc. excavation. and higher aut horities. work on roof. quarterly and yearly and communicated to concerned depts. 2. which look in to local level safety and accident prevention activities in collaboration with the Safety Committee and Safety Department. This committee is in existence since 1976. 4. workmen .

Canister Masks. Slogans. . are kept in the depts. Periodic mock drills are being organized Emergency control centers established. etc. Personal Protective Equipment : Shoes are provided once in a year to all employees including contra 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. Active role is being played in preparation of Off Site Emergency Plan being made by District Emergency Authority. An accident reduction contest is organized. Occupational Health : Occupational Health Centre is established. are displayed through out plant Safety Magazine is published 7. posters. Many competitions like slogans.5. 6. are organized on the occasion of National Safety Day Celebrations every year. One doctors and 2 nurses are working in Occupational Health Centre. It is operated round the clock . stories. Motivation : National Safety Day is celebrated every year. Emergency Planning & Preparednes s & Response: Emergency Plan is made and copies distributed to all concerned personnel. for use whenever and wherever those are needed 8. essays. PVC suits etc. etc. 9. Bulletins. Publicity : Posters.

This includes X-rays. stool exam. 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). ENVIRONMENT LABORATORY: Environment Cell is having an exclusive Environment Labo ratory equipped with modern monitoring/testing facilities. eye exam as p er the requirement under Factories Act 1948 ENVIRONMENT CELL AT GVG : GVG paper mill has established a separate. Lung function test. which indicates the commitment of the Industry in controlling the pollution. . Testing facilities available at Environment Laboratory.Periodical medical exams are being carried out for the identified personnel. dedicated ENVIRONMENT CELL for Water and Air pollution abatement. Clinical examination. audio metric. Blood exam.

). There are 11 Nos. The effluent after Secondary Treatment is pumped to Land Treatment. of mechanical surface aerators. and C.WATER POLLUTANTS AND TREATMENT MEASURES WASTE WATER TREATMENT: The main pollutants in the effluent discharged are Suspended Solids. PRIMARY TREATMENT: Wastewater is passed through bar screens and perforated screens to remove any foreign material and pumped to primary clarifiers (2 Nos.O. of each 7500 M . are dosed in to the aeration tank as food to the bacteria.D etc. 3 SECONDARY TREATMENT (ACTIVATED SLUDGE PROCESS): The effluent from the Primary Treatment is taken to an aeration tank of 25000 M volume. GVG paper mill ltd is the only mill discharging effluents upstream and drawing water from down stream . The settleable solids are removed from the bottom and clarified effluent from the top of the clarifier is taken to Secon dary Treatment . Nutrients like Urea and SSP (Single Super Phosphate).) of 6000 M each.O.O.O.D and C. each of 75 HP. 3 3 .D.D and then treated by Land Treatment process to remove even th e Colour of the effluents. B. From the aeration tank the effluent is taken to the secondary clarifiers (2 Nos. The wastewater from the mills is treated in Effluent Treatment Plant consisting of Primary Treatment to remove the suspended solids and Secondary Treatment (Activated Sludge Process) to remove B.

top layer of soil can be utilized for the treatment of Biodegradable Organic Waste water. The Mill also installed one Rotary Lime Kiln where the lime sludge (CaCO 3) is burnt to get burnt lime (CaO) to reuse in the Causticizing Process. 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.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. This is an additional benefit achieved through Land Treatment. Thus. part of it infiltrates down wards and part evaporates and part gets transpired by Plants. land treatment is well recognized as Living Filter all over the World. Considering such capability of land for treating wastewater. The remaining portion gets utilized under the influence of Land as Living Filter. The soil seems to be wor king as colour removal media which is otherwise prohibitively expensive treatment. As wastewater is discharged on land for treatment.O. where in the black liquor is fired in the furnace to recover and reuse the valuable chemical in the process. physical and biological) treatment processes occur in Land Treatment. B.S. It is also observed that the effluents after percolation through land is void of colour.S & Faecal Coliform are almost completely removed. The removal of constituents from waste water by filtering and straining action of soil are excellent in this RI system.D. Several conventional (natural. . T.

Besides the mills should also diversify its paper products so that different kinds of customers or . the company should expand its business and production thereof by investing some more capital. a fine distributing system and reasonable pricing policy for its products. prices and credit facilities offered. The company to become more competitive among the contemporary paper mills should perform still better in terms of quality. etc.ELECTRO STATIC PRECIPITATORS: The emissions from the boilers contain dust particles (Suspended Particulate Matter. Therefore to reap the advantages of the economies of scale. 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 . SPM) and contain gases like Sulphur dioxide and Hydrogen sulphide etc. CONCLUSION: GVG paper mills a well established unit with 40 years of existence is performing well in its business activities maintaining company customer relationship intact or improving day by day thanks to a quality of its product. distribution system.. The analysis made regarding customer satisfaction and the findings thereof reveal that GVG is performing well on all fronts. credit facilities offers.

the paper industry will grow gradually. Duty free imports of new and second hand machinery/equipment should be allowed for technology up gradation. cost conscious. As for the Indian paper industry is concerned. the following measures have to be taken for the industry to become more competitive y Improvements in infrastructural facilities like ports. and state government. will become quality oriented. railways. customer oriented so that they can become highly competitive in global environment. Revision of forest policy is required for wood based paper industry so that plantation can be raised by industry. and communication facilities. and the mills producing different paper products. . roads. y y y Import duty on waste paper should be reduced. cooperatives of farmers. Degraded forest land should be made available to the industry for raising plantations. If the above measures are taken up by the government. It should also target the international markets with its multi type of products thro ugh its export business.dealers will come under the fold of the company.

Sign up to vote on this title
UsefulNot useful