Professional Documents
Culture Documents
UNIT: KOVAI
In the first six decades of the Company's existence were primarily devoted to the
growth and consolidation of the Cigarettes and Leaf Tobacco businesses, the Seventies
witnessed the beginnings of a corporate transformation that would usher in momentous
changes in the life of the Company. ITC's Packaging and Printing Business was set up in
1925 as a strategic backward integration for ITC's Cigarettes business. In 1979, ITC
entered the Paperboards business by promoting ITC Bhadrachalam Paperboards Limited,
which today has become the market leader in India. In 2000, ITC forayed into the
Greeting, Gifting and Stationery products business with the launch of Expressions range of
greeting cards. A line of premium range of notebooks under brand “Paperkraft” was
launched in 2002. Years 2007- 2009 saw the launch of Children Books, Slam Books,
Geometry Boxes, Pens and Pencils under the “Classmate” brand. In 2008, ITC
repositioned the business as the Education and Stationery Products Business and launched
India's first environment friendly premium business paper under the “Paperkraft” Brand.
“Paperkraft” offers a diverse portfolio in the premium executive stationery and office
12
consumables segment. Paperkraft entered new categories in the office consumable segment
with the launch of Textliners, Permanent Ink Markers and White Board Markers in 2009.
Packaging
Virgin Recycled
1 Folding Box Boards 1 Coated Duplex Whiteback
2 Solid Bleached Boards 2 Coated Duplex Greyback
3 Coated High Burst Liner
Specialty
1 Liquid packaging 1 Barrier coated carton boards
2 Food grade packaging board 2 Biodegradable barrier boards
3 Cupstock 3 Cast coated boards
4 Antifungal Coated boards
13
Papers
1 Woodfree fine papers 1 Unbleached Kraft base
2 Absorbent Kraft 2 Cigarette Tissues
3 Opaque papers 3 Electrical insulation papers
4 Decor Surface, Printing & 4 Pharma Inserts
barrier papers Niche papers Superfine Printing
Graphic
1 Art boards 1 Playing card boards
2 Ivory boards 2 Cigarette Tissues
Each of the units specializes in a range of products. Together, these units produce
close to 5,50,000 ton/year of paper and paperboards that meet stringent quality
14
requirements across the world. All manufacturing units are ISO 9001, ISO 14001 and
OHSAS 18001 certified and meet strict Environment, Health and Safety norms.
15
2.3.1. Manufacturing process
The raw material for the manufacture of coated multilayered board is bleached
chemical pulp and waste paper, assorted paper waste, box board cuttings, coated book
stock, duplex cuttings, mixed waste, MWL (Manifold White Ledger), magazine, old news
paper, printer off cuts, pure white cuttings, sorted office paper, virgin duplex trimmings,
waste broke cut sheets, white blank news, news and pams, white broke and white office
record.
The purchased waste papers are in form of bales. The bales are charged to the
pulper through the conveyor belt. The slushed pulp from pulper at a consistency of 4 per
cent is sent to high density cleaner for removing heavy weight contraries and then to
double disc refiners for refining pulp to make it suitable for board making. The refined
pulp is sent to blend chest where rosin is added. The blended pulp is sent to machine chest,
where alum is added for maintaining required pH of the system. The chemicals rosin, alum
etc., are prepared in chemical additive plant which is situated near to the stock preparation
building. From the machine chest the pulp is sent to one overhead stock-regulating box
through one control refiner where final control of refining is done.
From the stock-regulating box, the pulp is metered to the approach flow systems of
top layer through basis weight value. The approach flow system consists of one off
16
machine white water silo, three stage centric leaning and three stage screening systems
where the pulp is cleaned to remove contraries like sand particles and shives from pulp.
After screening the pulp of a consistency of 0.6 - 0.8 per cent is sent to head box, which
delivers this pulp suspension on a moving endless forming wire. The water is drained from
the web formed on the wire and routed to machine silo where it is recycled back into
approach flow system.
The wet web leaves the top layer wire at around 11-12 per cent consistency.
Similarly for middle layer mixed waste paper are charged to the pulper through the
conveyor for slushing. The slushed pulp is processed through detrasher and high density
cleaner for removing the contraries. The pulp is further processed through three-stage
coarse cleaning, five stage centi cleaners, three stage fine screening and lightweight
screening. The cleaned pulp is then sent to thermo dispersion system for dispersing the
remained ink and other contraries uniformly throughput the pulp. The thermo-disposed
pulp is sent to blend hest from where the process is similar to that of top layer. For base
layer waste paper is used and the process is similar to that of middle layer. The raw
material used in the base layer is of better quality compared to middle layer.
The excess backwater from top layer is sent to flotation saveall where useful fiber
is recovered and sent back to process and clarified water is recycled back into process. The
backwaters of base layer and middle layer are combined and treated in a common flotation
saveall. The wet web from the all layers is couched into one single layer. The combined
layer is further dewatered to around 18 per cent on the base layer wire part, from where the
sheet is transferred to press for further dewatering takes place with the help of steam
heated cylinders. The steam is drawn from boiler. A precoating of starch is applied on the
surface of the board in the size press located within the dryer part.
The surface sized board is then is coated in the coating kitchen situated adjacent to
board machine building. The coated board is then passed through calendar for improving
the smoothness before it is reeled on the reel drum in roll form. The roll from reel drum,
weighing about 10 tons is taken to winder where it is cut into reels of the required size. The
cut reels are transferred to the finishing house area through reel handling conveyors and
17
lowerator. Here the reel order reels are packed in the reel-packing machine, sheet order
reels are processed in sheet cutters. The cut sheet is packed into reams and bales. The
packed reels and bales are weighed and sent to the godown from where they are dispatched
for market.
2.3.2.3. Energy
Agro wastes such as saw dust, de oiled rice bran, fossil fuels, raw lignite and coal
are fuels are used for energy generation.
18
Table 2.1. Generation of solid wastes
Waste Generation
Processes
Liquid Solid
Raw materials sorting - Plastics, wooden waste, iron waste, broken
glasses and mud
Paper feeding - Iron waste, Plastics and Jute waste
Pulping Effluent Metal waste, broken glasses, Plastics and
sludge
De-inking Effluent Sludge
Board manufacturing Effluent -
Coating Effluent Sludge
Rewinding - Solid waste
Packing - Plastics and wooden
Raw water treatment - Silt
Demineralization plant Effluent -
Boiler Effluent Flyash, Bed materials and packing waste
Effluent Treatment Plant Effluent Primary and Secondary sludge, Plastics
19
stages, from the bottom of convection section, from the bottom of Economizer and finally
from ESP.
• The condensate (waste steam) from the process having temperature of 80° C is
collected separately and used in boiler, which minimizes the fuel usage.
• PETAX filter is used for recycling of water as well as recovery of fiber from the
effluent.
20
2.7.8. Sludge Handling System
The primary clarifier underflow sludge and the excess secondary clarifier biomass
are pumped to a thickener. The thickened sludge is pumped to a press filter for dewatering
and the dewatered sludge is disposed of as land fill /sold to sundry paper mills.
Inlet
MLSS
Filter Thickener
sludge press
Outlet Secondar
Irrigation tank y clarifier
S- sludge 51
21
CHAPTER III
ENVIRONMENTAL INVENTORY
Methodology
In this study, system boundaries were set for production (Fig.3.2). Data collected
for this subsystem includes all energy, material, water inputs and environmental releases
that occur during the manufacturing processes. This process was repeated for several
22