ITC PSPD UNITS

Paperboards and Specialty Papers Division(PSPD)

ITC's Paperboards and Specialty Papers Division is India's largest, technologically advanced and most eco-friendly, paper and paperboards business. The business caters to a wide spectrum of packaging, graphic, communication, writing, printing and specialty paper requirements through its four world-class manufacturing units, 6 sales offices and a network of more than 50 dealers in India, along with an international trade network of 18 distributors / agents and 4 finishing operations close to the market for providing faster service to the customers. The product range includes: Packaging Virgin Folding Box Boards Solid Bleached Boards Recycled Coated Duplex Whiteback Coated Duplex Greyback Coated High Burst Liner

Specialty Liquid packaging Food grade packaging board Cupstock Cast coated boards Barrier coated cartonboards Biodegradable barrier boards Antifungal Coated boards

Papers Woodfree fine papers Absorbent Kraft Opaque papers Graphic Art boards Ivory boards Playing card boards Cigarette Tissues Unbleached Kraft base Cigarette Tissues Electrical insulation papers

The unit in Bhadrachalam is India's largest integrated pulping and paperboard manufacturing unit. It boasts of equipment supplied by internationally renowned suppliers for pulping processes, paper machines, web detection & inspection systems, and finishing & packing lines. Currently the unit produces high-end virgin and recycled boards for packaging and graphic applications, and fine printing papers. The Bhadrachalam unit manufactures and uses pulp made from ozone bleaching process. The use of ozone technology significantly reduces the load of toxins in the effluent discharged, and helps customers get a brighter, stronger product that is also environmentally responsible with the BOD (Biochemical oxygen on demand) and COD (Chemical oxygen on demand) level way below the National Standards Limits.

The Kovai unit currently focuses entirely on recycled boards, servicing requirements for both greyback and whiteback recycled boards, The Kovai unit is a benchmark in environmental performance - helping ITC turn solid waste recycling positive by consuming more paper waste generated than is generated internally. This is done by collecting waste from households and institutions and recycling it at this facility. The Tribeni unit specializes in fine papers and tissues and the product range from this unit comprises opaque papers for fine printing like the Bible, dictionaries, cigarette tissues, medical grade papers, anti-rust papers, electrical insulation papers, decor surface, printing and barrier papers. The production lines for cigarette component papers and communication papers have been upgraded in 2008 to ensure that all products continue to meet exacting international benchmarks.

The Bollaram unit manufactures specialty boards such as cast coated papers and boards, poly extrusion coated barrier boards and C2S art boards and ivory boards. This unit is BRC- IOP certified for food grade boards. All the 4 units of ITC PSPD are FSC-CoC (Forest Stewardship Council- Chain of Custody) certified enabling it to provide a diverse range of paperboards/paper with FSC certificate which is a gold standard in wood certification for ethical and legal sourcing. Supporting the cause of clean technology, ITC is a front-runner in introducing environment-friendly Elemental Chlorine Free (ECF) technology, and more recently, Ozone bleaching in India. ITC's focus on being a carbonpositive, water-positive, zero-solid waste disposal organization leads it to constantly develop ways of reducing, reusing and recycling. ITC has been Carbon Positive for five years in a row, Water Positive for eight consecutive years and Waste Recycling Positive for the last three years.

ITC's Paperboards and Specialty Papers business has also been a first-mover in the field of collecting and recycling post-consumer waste from residential localities, corporate and educational institutes. ITC reaches out directly to consumers with its Wealth Out of Waste (WOW) campaign, that has been successfully implemented in select locations across southern India, and has plans to expand into other locations across the Country.

ITC PSPD Kovai Unit

In 2004, ITC acquired the paperboard manufacturing facility of BILT Industrial Packaging Co. Ltd (BIPCO), near Coimbatore, Tamil Nadu. Commenced commercial production on 29th march 2004.

Location of the Plant : Foot Hills of Nilgirs, 42 kms from coimbatore, Vivekanandapuram, Thekkampatty Village, Coimbatore, Tamil Nadu.

Certification:

     

ISO 9001 : 2001 ISO 14001 : 2004 OSHAS 18001 : 2007 British Safety Council Awards 2007, British Safety Council Awards 2008, British Safety Council Awards 2010,

Present Scenario:

   

Production Capacity Product GSM Range Power Generation

: : : :

90,000 TPA. Duplex Board 230 390 8MW

S.No 1 2 3 4 5

GRADE Coated Board Grey Back Coated Board white Back Coated match Shell Board Duplex Board Grey Back Cone Board

PRODUCT Double Coated Grey Back Double Coated white Back Single Coated Board Uncoated Board 100% Grey Pulp Board

GSM RANGE 230 390 240 390 270 300 250 300 250 360

Product:

o Top coat (Blade) o Pre coat (Bar) o Top Liner (Deinked Pulp) o Filler Liner (Recycled Waste Paper) o Back Liner (Recycled Waste Paper)

LEAN MANUFACTURING MANAGEMENT STRUCTURE

PSP DIVISIONAL LEVEL

DIVISIONAL STEERING BOARD

KOVAI UNIT PLANT FACILITATOR

UNIT STEERING BOARD

SKILL DEVELOPMENT PILLAR TEAM

QUALITY PILLAR TEAM

EHS PILLAR TEAM

PLANNED MAINTENANCE PILLAR TEAM

PRODUCTION EFFECTIVENESS PILLAR TEAM

AREA LEVEL

AREA EFFECTIVENESS TEAM (eg., Stock Preparation , board m/c,...etc) AETS

SHIFT LEVEL

PROCESS & ASSET CARE TEAM 1,2,3

PACTS

PACT TEAMS:

Stock AET Team Pulper Stock AET Team Krima Stock AET Team Chemical Utility AET Team ETP / WTP / DM Utility AET Team Boiler TG
B/Mc AET Team Wet End

B/Mc AET Team Dry End

Utility AET Team Fuel & Ash

B/Mc AET Team Coater Machine B/Mc AET Team Coating Kitchen B/Mc AET Team Re Winder

SET Engg Team 1 SET Engg Team 2

F/H & Godown AET Team Jagenberg

SET Admin Team 1

F/H & Godown AET Team Pasebon