EXECUTIVE SUMMARY

To study the organizational structure and how the management control various
departments for the attainment of the organizational objectives.

The report gives detailed information about the overall operations performing
within the Tamilnadu Newsprint and Paper Ltd. The process flow have been
examined and the report have been given on the analysed information
obtained from the organisation.

The report contains information about Tamil Nadu Newsprint and Papers Ltd
that gives an unrivalled in-depth knowledge about internal businessenvironment of the company: data about the owners, senior executives,
locations, subsidiaries, markets, products, and company history.

Another part of the report is a SWOT-analysis carried out for Tamil Nadu
Newsprint and Papers Ltd. It involves specifying the objective of the company's
business and identifies the different factors that are favorable and
unfavourable to achieving that objective. SWOT-analysis helps to understand
companys strengths, weaknesses, opportunities, and possible threats against
it.

To learn functioning and operations of different departments in an

organization.To have knowledge about the huge management practices and
get the practical knowledge of what we have studied. To know the industries
expectations toward the management students.

In the part that describes Tamil Nadu Newsprint and Papers Ltd competitors
and the industry in whole, the information about company's financial ratios is
compared to those of its competitors and to the industry. The unique analysis
of the market and companys competitors along with detailed information about
the internal and external factors affecting the relevant industry will help to
manage your business environment.
1

1.1

INDUSTRY PROFILE

1.1.1 EVOLUTION AND GROWTH OF INDUSTRY

Paper is the thin material mainly used for writing upon, printing upon or
packing. It is produced by the amalgamation of fibres, typically vegetables fibres
composed of cellulose, which are subsequently held together by hydrogen bonding.
While the fibres are usually natural in origin, a wide variety of synthetic fibres, such as
polypropylene and polyethylene, may be in corporated paper into as a way of
imparting desirable physical properties. The most common source of these kinds of
fibres is wood pulp from pulpwood trees. Vegetable fibres materials such as cotton,
hemp, linen and rice are also used.
India first machine-made paper was manufactured in 1812. During this time
there were 15 mills with a total production of lakh tonnes. In India the soft wood is the
principle raw material used for making paper especially newsprint and high class
printing papers. With rise in population and broadening of education the demand for
paper has been constantly escalated. Owing to very narrow forest resources wood
pulp is in shortage. As soft woods grow in temperature climate India is in short supply
of such woods. Thus, in such circumstances the bamboo became their major raw
materials for the manufacture of paper in the country. As it grows very quickly even
after cutting.
The earliest efforts in mechanizing the paper industry in India could be traced
to the beginning of 19th century when the Baptist missionary. William Carey stared a
paper path of government. Meantime in 1895, the Indian paper making association
was established and it rendered a proud service to paper industry.
1.1.2 ORIGIN OF PAPER
The art of paper making was first discovered in china its origin was kept as
secret by the Chinese for a long time. Then the art of paper making slowly travelled
westward and reached Samarkand in west Asian. Then the used and manufactures of
paper gradually along southern shores of Mediterranean. After that though Spain it
reached morocco and then spread widely all over the world.

Indian paper industry has created sustainable livelihood in rural areas and has
helped generating employment for the local population especially for women to earn
their livelihood.
1.1.3 LIST OF MARKET PLAYERS
There are many market players in paper making industry who play an vital role in
their selling their Products.

Ballarpur Industries Limited

West Coast Paper Mills Limited
Andhra Pradesh Paper Mills Limited
Seshasayee Paper And Boards Limited

1.2 COMPANY PROFILE

1.2.1 BACKGROUND OF THE COMPANY
Tamil Nadu Newsprint and Papers Limited (TNPL) was formed by the
government of Tamil Nadu in April 1979 as a public limited company under the
provisions of the companies act 1956. It is one of the most environmentally compliant
paper mills in the world. Tamil Nadu Newsprint and Papers Limited (TNPL) are
engaged in the production of newsprint, and printing and writing paper using bagasse
as the primary raw material. The company operates in two business segments,
namely, paper and energy. Tamil Nadu Newsprint and Papers Limited had a capacity
of 90000 tons per year when it was started and now it has a capacity of 245000 tons
per year and the company has emerged as the largest bagasse based paper mill in
the world consuming about one million tons of bagasse every year. Implementation of
increasing the capacity to 400000 tons is on the way and it expected to have that
capacity from July 2010. Tamil Nadu Newsprint and Papers Limited have obtained the
ISO 9001-2000 certification from RWTUV of Germany for development, manufacture
and supply of newsprint and printing and writing paper. In 1993 the wind farm at
Devarkulam was commissioned on December and that at Perunguadi.
The company undertook to double its existing capacity. The company has
signed an MOU with Quena newsprint, Egypt for providing technical assistance and
support for erection and commissioning of a newsprint and paper mill in Egypt in the
year 1998. Photocopier paper named TNPL COPIER was developed to meet the
requirement of the customer with 75% chemical bagasse pulp. TNPL is the first
commercially successful bagasse based newsprint plant in the world. Tamil Nadu
Newsprint and Papers Limited is the first CDM project in world in pulp and paper
industry. It is also the first CDM project in India in the waste management sector
registered with UNFCCC. It is the only paper mill in India assisted by the World Bank.
Tamil Nadu Newsprint and Papers Limited have installed tallest chemical recovery
boiler or large capacity in India.
TNPL primarily uses bagasse an environmentally benign raw material, for
producing paper in substitution of wood and there by avoids denudation of trees in
4

more than 40,000 acres every year. TNPL has committed itself to making a positive
contribution to the communities and societies where it operates.
1.2.2. NATURE OF BUSINESS CARRIED
Tamil Nadu Newsprint and Papers Limited (TNPL) is an India-based company,
which is engaged in producing paper. The Company is engaged in producing
newsprint, and printing and writing paper. The Company operates through three
business segments: Paper, Energy and Cement. TNPL is committed to manufacture and
supply eco-friendly papers to customers satisfaction with the emphasis on continual
improvements in its quality management systems. Meeting customers requirement with ecofriendly raw materials (viz.., Baggasse) for paper making through continuous process
improvements is TNPLs Quality policy. The Company offers a range of paper products,
which include TNPL ultra white Maplitho/Print Vista, TNPL Elegant Maplitho, Hi-Tech
Maplitho, TNPL pigment paper, radiant printing, Ace Marvel, hardbound notebook,
TNPL offset printing, creamwove, Copy Crown, TNPL copier, Students' Favourites,
Super Print Maplitho and Perfect Copier. The Company operates a factory in Pugalur
in Karur district, Tamil Nadu. The Company's factory produces around 1,180 tons of
paper per day. The Company exports approximately0.2 of its production to around 50
countries.
1.2.2 THE VISION
To be the market leader in the manufacture of eco-friendly world class
papers adopting innovative technologies.
1.2.3 THE MISSION

Attain leadership in paper industry.

Promote the usage of Baggasse in the manufacturer of Newsprint and Printing

and Writing paper.

Minimize environmental impact and become an environment friendly
organization.

1.2.4 PRODUCT OR SERVICE PROFILE

Examination paper
5

Note book
Calendars
Copier
Pigmented papers
Super Printing Maplitho
Coating base paper

1.2.5. PRODUCTION CENTRES / BRANCHES

The Tamilnadu Newsprint And Paper Limited is headquartered at
Guindy, Chennai. The production factory is located at kagithapuram, Karur.
The branches were located at Calcutta, Delhi, Bombay, Cuttak, Pune, Bangalore,
Cochin, Chandigarh, Visakhapatnam, Jaipur. Each branch office has the godown and
is functioned by the company.

2.1 ORGANIZATIONAL STRUCTURE

TNPL follow absolute dedicated approach. The organization of its
manufacturing operations is based on product divisionalisation in to group of products
in which are similar in technology or manufacturing process. Each group is
constituted by divisions or profit centres. Each of these group, are led by absolute
manager. A central manager leads the corporate function. Some of these functions in
turn are reported to the managing director.

2.2 ORGANIZATIONAL OUTLOOK :

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Chairman & Managing Director

Director
Director (Operations)
Director
Deputy Managing Director
Area of Operation
Main production
Raw materials for production
Production range / Service range
Number of machines
Number of office staff
Number of workers at factory

Thiru C V Sankar IAS

Thiru T Udhayachandran IAS
Thiru R Mani
ThiruKumaravelu N
Thiru A Velliangiri
Kagithapuram, Karur.
Printing and Writing papers
Baggase,Hardwood,Softwood,DIP
World wide
57
810
2500

2.3 ORGANIZATIONAL CHART

MANAGING DIRECTOR
DEPUTY MANAGING DIRECTOR

CHIEF GENERAL MANAGER

GENERAL MANAGER

CHEIF GENERAL
MANAGER
(OPRERATIONS)

DIRECTOR

DEPTY GENERAL
MANGER

(FINANCE)

(TECHNICAL )

CHIEF GENERAL
MANGER
(FINANCE)

GENERAL
MANAGER
(MARKETING)

CHIEF GENERAL
MANAGER
(MARKETING)

GENERAL
MANGER

GENERAL
MANAGER

GENERAL
MANAGER

GENERAL
MANAGER

(HR)

(M&I)

(PAPER)

(PRODUCTION)

3.1 FINANCE DEPARTMENT

Finance department manages the fund available for the operations of the
business, by making a balance between the fund inflow and fund outflow. The
management of all activities related to finance requires considerable expertise and
specialized knowledge of banks, financial institutions, the different sources of finance
and ways to profitability utilize these funds. Finance Manager directly does the
planning, organizing, directing and controlling financial activities in the society.
3.1.1 FINANCE DEPARTMENT STRUCTURE
Finance department is headed by finance manager. Finance manager reports
to the General Manager and in certain strategy and urgent issues directly report to
managing director and take decisions. Finance Manager works in the coordination
with accounts manager, production manager, marketing manager, HR managers.

3.1.2 DUTIES AND RESPONSIBILITIES OF FINANCE DEPARTMENT

Develop standard accounting procedures to improve financial operations

efficiency.
Review annual budgets and recommend any changes if needed.
Assist in account payable and receivable activities.
Generate financial reports related to budgets, account payables, account

receivables, expenses, etc.

Ensure accurate calculation and distribution of salaries and other benefits to

employees.
Establish accurate forecasts regarding expenses and revenues and manage
regular reporting requirements.

3.1.3 FUNCTIONS OF FINANCE DEPARTMENT

The companys overall cash inflow and outflow were stabilised by the finance
manager.

The corporate office finance and accounts department reforms the following
functions.

The finance & accounts department arranges term loans from the (DB) World
Bank IFCI and other commercial banks.

Arranges for working capital loan (cash credit)

The company working capital limit is 70 Crores from contortion banks

consisting of Andhra Bank, Canara Bank, Indian Bank & Indian Overseas
Bank, K.V.B bank, Syndicate Bank of Patiala, State Bank of India.

Management of firms assets structure.

Financial analysis, planning and control.
Management of firms financial structure.
Estimating capital requirement.
Determining sources of fund.

3.2 MARKETING DEPARTMENT

The marketing functions are done at corporate office in Chennai and the
10

factory at kagithapuram. The company has branch offices at Bangalore, Calcutta,

Delhi, and Mumbai. Each branch office has its own go down and is functionated by
the company. It also operates in place like Cochin, Luck now, and Cut tack, which are
not maintained by the company. The marketing is headed by the director (Finance)
the marketing operations are comprised.
There is a good demand for the companys products, despite the premium
prices. Quality of both Newsprint & printing & writing paper are comparable to
imported products prices much lower.
3.2.1 MARKETING DEPARTMENT STRUCTURE

3.2.2 DUTIES AND RESPONSIBILITIES OF MARKETING DEPARTMENT

3.2.2.1 Strategy
11

The senior member of the marketing department takes responsibility for setting
marketing strategy in line with overall company strategy and objectives
3.2.2.2 Market Research
Market research is a key responsibility for the marketing department. Research
helps the company identify market opportunities and gain a better understanding of
customer needs
3.2.2.3 Product Development
The marketing department works with Internal or external product development
teams to develop new products or improve existing ones. The department analyzes
sales of existing products and identifies gaps in the product range where there may
be opportunities for the company.
3.2.2.4 Communications
Marketing departments plan campaigns and develop communications material
to promote products and services to customers and prospects. Depending on their
available budgets, they may plan advertising campaigns, develop e-mail marketing
programs, create promotional content for the company website, write press releases
or product publications, such as product leaflets, company brochures, product data
sheets or customer newsletters.
3.2.2.5 Sales Support
Cooperation between the sales and marketing departments can improve sales
performance and speed up business growth.

3.2.3 MARKETING POLICY

12

TNPL targets to sell around 4,00,000Mts per year, which were achieved every
year. They sell 55000 Mts of Copier, Exports 80000 Mts of reel papers and other
domestic orders were sold around 265000 Mts. The orders are collected from the
various retailers and the same will be forwarded by the indenters to marketing
department TNPL. The marketing department consolidates the orders and gives
information to production department for manufacture of required paper with the date
of paper dispatch. The production department produces the particular variety of paper
and delivers it to the marketing godown. Then the marketing department will inform to
the customer and the head office marketing department. Then the finished product
will b arranged for transportation.
3.2.4 DISTRIBUTION CHANNELS
TNPL has 4 major segments of market through which their products have been
sold or purchased. They are as follows:

Government
Export
Domestic
Direct

3.2.5 MARKETING NETWORK

TNPL has its marketing branches throughout the nation in order to connect
with the entire country. The branches were located at Calcutta, Delhi, Bombay,
Cuttak, Pune, Bangalore, Cochin, Chandigarh, Visakhapatnam, Jaipur. Each branch
office has the godown and is functioned by the company. The marketing functions
start from Madras Corporate office and the factory and Pugalur. The marketing
department is headed by the Director finance. He assists the day-to-day affairs at the
corporate office by the manager marketing, who in terms assisted by senior sales
officers and sales assistants. The site office is assisted by the chief manager
marketing.

3.2.6 PRODUCTS OF TNPL

13

TNPL offers high-quality surface sized and non-surface sized paper to suit the
needs of modern high speed printing machines. TNPL's cutting edge technology
backed by experienced professionals ensures quality products to customers. TNPL
manufacturing processes are equipped with state-of-the-art control systems to
maintain critical quality parameters on line. The paper produced by TNPL is ecofriendly as the pulp is manufactured out of renewable raw material and is subjected to
Elemental Chlorine Free bleaching. As the paper is acid free, it has a longer colour
stability and enhanced permanency in terms of strength characteristics.
TNPL caters to the requirements of multifunctional printing processes like
sheet-fed, web offset, and digital printers. The paper reels have uniform profile with
strength properties to cope even with high speed machines. TNPL manufactures
Printing and Writing Papers in substances ranging from 50 GSM to 110 GSM.

TNPL Ultra White Malipatho

TNPL Elegant Malipatho
Ace Marvel
Perfect Copier
TNPL Copier
Copy Crown
TNPL Pigment Paper
Hardbound Notebook
Cream wove

3.2.7 EXPORT
TNPL exports its finished products to 17 countries. Despite severe
competition and only a gradual upward movement in the international prices. TNPL
has achieved phenomenal growth in the area of exports. TNPL has broad based
the exports and achieved the highest ever exports of 25262 Mts valued at Rs 77.40
against the 18760 Mts of wood free of paper valued at Rs 47.77 crores exported in
the previous year.
Being an ISO 9001 accredited company, TNPLs efforts have been oriented
towards developing new products to suit specific customer and specific endues. This
ISO 9001 quality assurance procedure ensures consistent quality and assures in
carrying out timely corrective action. In recognition of TNPL export performance, the
Organization has bagged the Special Export Award from CAPEXIL for the 9th
consecutive year. The company continues to focus on export of printing and writing
14

paper as a corporate philosophy. TNPL has established a wide sales network

consisting of 54 domestic dealers and 9 sales agents in overseas market. TNPL
maintains countrywide branches in 9 major cities. The Marketing function
encompasses one of the most modern comprehensive information management
systems which provide real time customer and market analysis

3.3 HUMAN RESOURCE DEPARTMENT

TNPL realizes that the continued success of any organization depends on a
healthy human resources policy. TNPLs Human Resources policy focuses upon
enthusing the human resources to be innovative to keep ahead of competition. As an
15

enlightened employer the company has always been concentrating on optimizing the
labour productivity and continuous efforts have been taken to improve the same.
Some of the initiatives by the company in line with the above objectives are given
below:
In-house training programmes are conducted on topics like Team Building,
Personality Development, Safety, Inter-personnel skills, productivity and so on.
Besides the employees are also being sponsored for training programmes in
the relevant areas organized by reputed Institutions. Performance Appraisal plays a
significant role as a tool and technique of Management development and growth. Key
Result Areas (KRA) have been identified and responsibility, accountability, objectives
and targets are defined for these KRAs. The results of these KRAs are reviewed on
continuous basis and corrective measures initiated appropriately.
The philosophy of Total Quality Management (TQM) integrating all activities of
the organization coupled with a customer-centered focus has been taken-up. Suitable
projects have been identified and implemented. Company is nurturing a participative
atmosphere of redressing the grievances of the employees for ensuring peaceful
working environment. Amicable Wage settlements are reached with the Trade Unions
and harmonious industrial relationship is being maintained. TNPL is providing direct
employment for 1788 persons and indirect employment for about 5000 persons

3.3.1 HUMAN RESOURCE DEPARTMENT STRUCTURE

.
GENERAL MANAGER
(HR)

16

MANAGER
(Establishment)

AGM

STAFF

MANAGER

MANAGER

(Administration)

(Welfare)

AGM

AGM

STAFF

STAFF

MANAGER
(Industrial
Relation)

AGM

STAFF

3.3.2 DUTIES AND RESPONSIBILITIES OF HUMAN RESOURCE DEPARTMENT

HR department main function of all the organization is recruitment of

employees, staffs, workers, etc.,

After the recruitment the company has to provide the training to the selected
candidates and providing the good working environment to them.

To maintaining the records and files of each staff and workers and follow up in
matters concerned with pay increase, promotional activities etc.,

To maintain proper base on with the accounts department regarding payment

of salary, wages etc., by giving proper information.

By keeping the proper records about the employees it will provide the
informations regarding employees it is used to solve if any legal problems.

To enrich the employees co-ordination among the employees.

17

3.3.3 PERSONNEL ADMINISTRATION

Personnel Administration is a method of developing the capabilities of the
employees in the factory so that they get maximum satisfaction out of their work and
give their best efforts to the organization so the organization also gets the benefits
indirectly.
The Personnel Department in TNPL is mainly consists of following:

Establishment

Industrial relations

Human Resources and Development

3.3.3.1 Establishment
Establishment is that part of personnel and administration management
process which is primarily concerned with the human constituents of an organization.
The following functions are comes under the establishment.

Recruitment
Promotion
Selection
Increment
Induction
Bonus
Training
Employment

Recruitment
Employees recruitment is the very important process in the organization. So
every organization has to recruit and retire the employees. Before recruitment, the
department has to make detailed study and determine the activities of the
department. If there is any vacancy, the company has to give the advertisement.
Selection
Selection of the employees made through oral or written test it depends upon
job requirements and skills necessary for the company. After the satisfaction of the
HR department the candidate can get the appointment.
Induction
18

It is conduct after the candidate selected in the interview or after getting the
appointment order. Before joining into the job all candidates have to attend the
medical examination. After some certificate verification formalities are the over, the
HR trainer will provide the details about the organization and nature of the job which
he is going engage, and introducing their department heads.
Training
Training is the important aspect in all kinds of jobs. After the appointment of the
candidates they have to get the training regarding their respective department works
it will take normally two years, during this training period the candidates can get
stipend.
Promotion
Promotion is one of the welfare activities of the HR department. Without having
any promotion the employee cannot get the job satisfaction, the promotional activities
will enhance the output of the company. It will provide the unions and management
under the industrial dispute Act, with regard to officers, promotion will be done as per
the policy of the management.
Increment
All the companys regular employees are having the eligible to get the yearly
increments. The increment will vary depends upon the posting.
Bonus
Every year bonus will be paid to the employees of the festival of Diwali and
Pongal. For executives and workman they will get 20% as bonus and 35 days wages
as a bonus are paid subject to ceiling of maximum of Rs. 10,000.
Employment
During the course of the training there are 1820 plus employees are on
permanent basis are on roll, of which 1000 are workmen. In addition to this, contract
labours around 1600 are also there. In total around 3420 employees are working.

19

3.3.3.2 Industrial Relation

The word industrial relation denotes the good relationship between
management, employees and Government in any industry. In TNPL they are
maintaining the cordial relationship with their employees.
3.3.3.3 Human Resource Development
HRD must concentrate on the development of the overall organization. It has
to improve the organization diagnostic and problem solving capabilities and make the
organization more effective one. HRD in TNPL mainly focus on Health, Safety and
Welfare measures.
3.3.4 WORKING HOURS IN THE COMPANY
The employees in the company were working on shift basis. The different
shifts followed in the organisation
A- Shift from 6.00 AM to 2.00 PM
B- Shift from 2.00 PM to 10.00 PM
C- Shift from 8.00 PM to 4.00 AM
G- Shift from 8.30 AM to 5.30 PM
3.3.5 CORPORATE SOCIAL RESPONSIBILITY (CSR)
TNPL, as a responsible corporate citizen, has ingrained the philosophy of
Corporate Social Responsibility deeply into its value system. The company is
consistently taking up various community welfare initiatives for the benefit of the
people living in neighbouring villages. During the year 2009-10, the company has
spent an amount of about Rs.2.63 Cr. for various CSR activities. For the year 20102011 an amount of Rs.3 Cr. has been allotted for various CSR activities. The amount
has been spent under FIVE broader heads viz.,

Education

Health care

Socio Economic Development

20

Environment

Culture and Heritage

3.3.7 EXIT POLICY

Since TNPL is an government company, there wont be any hard formalities to
quit their jobs. The employees can quit their job through regular quitting process. The
employees are not cornered or interviewed for quitting their job.

3.4 PRODUCTION DEPARTMENT

Production is a sequence of technical processes requiring either directly or
indirectly the mental and physical skill of craftsmen and consists of changing the type,
21

shape, size, and properties of materials and ultimately converting them into more
useful article. Production means creation of utilities which factors include the activities
or procurement and utilization of production viz., manpower, material, machineries
and buildings.
3.4.1 PRODUCTION DEPARTMENT STRUCTURE

22

3.4.2 SECTIONS IN PRODUCTION DEPARTMENT

Production Department in TNPL headed by the General Manager and has the
following two major areas.

Pulp Mill
Paper Machine

The main task of this development is to achieve the target production with good
quality of Newsprint and Writing paper. Chief Managers, Deputy Managers, Engineers
and operators assist him.
3.4.2.1 PAPER MACHINE
The paper machine area has two machines namely PM#1, and PM#2. The
machine 1 was supplied by Beloit Walmsely, UK. It is twin wire former having a deckle
width of6.8m, which produces newsprint of 49 GSM paper. The machine is also
capable of producing printing and writing papers between the weight ranges of 40-80
GSMs. The paper machine 2 is designed to achieve high quality paper. This machine
has an on line process basis to weigh moisture and ash. Converting, finishing and
packing lines have been provided for production of finished paper in reels or sheets of
required dimensions. Facilities automatic reel handling and reel wrapping systems.
The sheeting system consists of 3 cutting machines salvage sheeter and micro
processor based 2 guillotine machines with an aggregate capacity of 180 tpd.
3.4.2.2 PULP MILL
The Company produces the following varieties of pulp to manufacture
Newsprint, printing and writing papers.
PULP MAKING PROCESS
PULPING is a process of separation of fibrous-mass from the raw materials.
There are three types,

HARDWOOD PULPING
CHEMICAL PULPING

For all these process wood is mainly used as raw material. In this process the
undesirable components like sand, stone etc., can be removed.
HARDWOOD PULPING
23

It is a process in which wood pulp is ground well and mixed with steam. The
presence of heat softens the lignin and grinding process pulls the fibre out. This
process is not often used because the paper obtain from this are less strong. They
are mainly used for printing papers such as Newsprints, Telephone Directories.
CHEMICAL PULPING
The chemical pulping includes Soda pulping, Sulphate pulping and Sulphite
pulping. The important one among these is Kraft pulping. Soda pulping process is
carried out by treating the wood and chips with caustic soda solution to fibre by
cooking them in pressurized vessels. In Sulphate pulping the woodchips is cooked
with Sulphurous acid and salt of this acid. Sulphate pulp is used I the manufacture of
bond writing high grade book and other fine papers.
3.4.3 COOKING PROCESS
The Cooking process contains three types.

Continuous process
Bleaching process
Stock preparation process

3.4.3.1 CONTINUOUS PROCESS

The chips and cooking liquor are fed at a constant rate into the top of the
digester and the chips moves downwards in a continuous manner for discharge from
bottom.
In both the process the cooked chips are discharged from digester under pressure.
The pulp coming out of the digester is very dark in colour and could brow stock. It is
thin washed and further sent to bleaching process. In this industry they follow
continuous process.
3.4.3.2 BLEACHING PROCESS
Bleaching is a process to remove the unwanted particles and to increase the
pulp properties. The bleaching process usually consists of Chlorination treatment
followed by an alkaline extraction after which further bleaching treatments are
applied. The Chlorination stage may be made with chlorine or with a hypochlorite
24

mixture or CIO2. Further the reagents used in bleaching process and H2o2, CIO2,
hypochlorite. So incase of high yield pulp Zn or Na hydrosulphite can be used. After
bleaching the pulp were drawn at different proportions. The obtained pulp is used for
making paper through paper machine.
3.4.3.3 STOCK PREPARATION PROCESS
Most of the pulp cannot be used for paper making as it comes directly from the
pulp mill. The obtained final desired qualities, pulp having different characteristics are
blended with dyes and special additives. Basically, this operation consists of passing
the pulp repeatedly between sharping moving bars that cut and abrade the fibers.
This improves fibers- the fiber bonding, uniformity, more dense, less porous
depending on the king of paper to be made.

25

3.4.4 PROCESS LAYOUT

PULP MILL

HARDWOOD

CHEMICAL
BAGGASE

DE-INK PAPERS

STOCK PREPARATION

BLENDING

OPTICAL BRIGHTNING AGENT

PAPER MACHINE

WIRE

PRESS

DRYERS

SIZE PRESS

AFTER DRYERS

CALENDERING

WINDERS
CONVERTING & FINISHED GOODS
26

3.4.5 PAPER MAKING PROCESS

The following are the main parts of paper machine and its functions.

THE STOCK INLET

THE HEAD BOX

THE FOUR DRAINER LINES

THE PRESS SELECTION

THE DRYER SECTION

THE CALENDER SECTION

WINDING

ROLL FINISHING
3.4.5.1 STOCK INLET
The objective of the inlet into piping is to distribute the paper making fibers
uniformly across the machine from back to front.
3.4.5.2 HEAD BOX
The pressurized flow box distributes the pulp the moving forming wire.
3.4.5.3 FOUR DRINER LINES
The endless moving wire forms the fibers into a sheet enables a furnish to drain
by gravity and dewater by suction.
3.4.5.4 PRESS SECTION
The sheet is conveyed through a series of presses where additional
water is removed and the wet is consolidated.
3.4.5.5 DRYER SECTION
Most of the running water is evaporated and the fibre bonding develops as the
paper contacts a series of steam-heat cylinders.

27

3.4.5.6 CALENDER SECTION

The sheet is pressed between multi rolls to reduce thickness and smooth
the surface.
3.4.5.7 WINDING SECTION
The function of the winder is to be to cut and wind the full width, large
diameter paper reel into suitable size rolls. It is then wrapped and sent to the
customers directly.
3.4.5.8 ROLL FINISHING
The steps in roll finishing are weighing, wrapping, crimping, heading and
labelling.
3.4.6 QUALITY CONTROL DEPARTMENT
The quality control function in many paper mills is now undergoing with some
changes. The old approach to quality consisted of setting up of a quality control
department, making spot checks on incoming material, alone end of the plant performing
some in process tests and finally conducting evaluation of the finished product. Some
statistical analysis was included if such specialized talent was available. The competitive
market of the future will demand much more.
In progressive mill the classical quality control function just described is
beginning to be replaced by the concept of total quality management. This involves the
orderly co-ordination of all functions that relate to product quality even to seemingly
unrelated areas such as purchasing, engineering and accounting shipping and
warehousing. If starts with a management commitment to a total quality effort that
impacts every phase of the company.
The function of the quality control department is to measure quality keep the
score and measure the performance. The responsibility for quality lies with everyone in
the production system.

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3.4.6.1 FUNCTIONS OF QUALITY CONTROL DEPARTMENT

Testing the ongoing product for defects/deviation and informing production

department for taking corrective steps.

Certification of output and maintaining parent roll history for future analysis of
products, companies etc.

Inspection of joints and conducting Operator- Wise Reel Joint Performance

Tests.

Inspection of finishers performance & reporting.

3.4.6.2 PROCESS CONTROL COMPUTER REPORTING SYSTEM:

A computer scan of ongoing product i.e. paper is continuously taken in the paper
machine cross direction and automatically recorded for the following reports.

Parents roll quality report highlighting GSM moisture and caliper.

Grade Report

Profile Report

Production, Run Time and Loss Report

Day Report

3.4.6.3 ROLL OF QUALITY CONTROL DEPARTMENT IN COMPLAINTS AND

PRODUCT DEVELOPMENT:

Visiting the customer for complaints investigation.

Analyzing the complaints and advising the production department for quality
improvement.

Attending to product trails at frequent intervals, arranged by the marketing

department to get first-hand knowledge about their product and its performance
of competitor-product.

Invoice outstanding not more than 90 days of the customers.

Throughout the year the customer should have achieved the minimum quota.

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3.4.7 PURCHASE DEPARTMENT

The purchasing department is an organisational unit of a firm whose duties
include some part or all of the purchasing function. This disconnection between function
and, department is not always appreciated or understood by top management. The
purchasing function is usually performed most economically and efficiently by a
specialised, centralised purchasing department, directed by a skilled purchasing
manager.
However, the purchasing function does not have to be performed in such a
manner. In theory, it can be performed, and in practice, it sometimes is performed by any
number of different company officers or departments.
The functions of purchasing department are varied and wide which are based
upon different approaches. The purchasing activities may be divided into those that are
always assigned to the purchasing department and those that are sometimes assigned
to some other department.
3.4.8 ROLE OF PURCHASE MANAGER

Manage and develop the purchasing function for the company, managing a team
of 4-6 persons.

Develop and update purchasing policy and planning.

Manage of purchasing information and systems, and review commodity strategy

with the management team.

Manage and develop the existing and potential supplier pool and update the
Approved Vendor List.

Search for new potential suppliers then develop and set up a supplier data base.

Negotiate with local and international suppliers; prepare price comparisons, cost
saving budgeting and targeting.
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Negotiate and set up frame contracts. Effective & proactive liaison with other
departments as necessary to forecast, plan to meet purchase deadline, to
bundling of demands for necessary.

Make or buy analysis of stands production and decision in cooperation with

management.

3.4.9 EXPORT
TNPL exports its finished products to 17 countries. Despite severe competition
and only a gradual upward movement in the international prices. TNPL has achieved
phenomenal growth in the area of exports. TNPL has broad based the exports and
achieved the highest ever exports of 25262 Mts valued at Rs 77.40 against the 18760
Mts of wood free of paper valued at Rs 47.77 crores exported in the previous year.
Being an ISO 9001 accredited company, TNPL s efforts have been oriented
towards developing new products to suit specific customer and specific endues. This
ISO 9001 quality assurance procedure ensures consistent quality and assures in
carrying out timely corrective action. In recognition of TNPL export performance, the
Organization has bagged the Special Export Award from CAPEXIL for the 9th
consecutive year. The company continues to focus on export of printing and writing
paper as a corporate philosophy. TNPL has established a wide sales network consisting
of 54 domestic dealers and 9 sales agents in overseas market. TNPL maintains
countrywide branches in 9 major cities. The Marketing function encompasses one of the
most modern comprehensive information management systems which provide real time
customer and market analysis. The company is equipped with state of the art storage
and shipping systems for fast and efficient despatch.
TNPL realises that the continued success of any organisation depends on a
healthy human resources policy. TNPLs Human Resources policy focuses upon
enthusing the human resources to be innovative to keep ahead of competition. As an
enlightened employer the company has always been concentrating on optimizing the
labour productivity and continuous efforts have been taken to improve the same. Some
of the initiatives by the company in line with the above objectives are given below:
In-house training programmes are conducted on topics like Team Building,
Personality Development, Safety, Inter-personnel skills, productivity and so on. Besides
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the employees are also being sponsored for training programmes in the relevant areas
organised by reputed Institutions.
Performance Appraisal plays a significant role as a tool and technique of
Management development and growth. Key Result Areas (KRA) have been identified
and responsibility, accountability, objectives and targets are defined for these KRAs. The
results of these KRAs are reviewed on continuous basis and corrective measures
initiated appropriately.
The philosophy of Total Quality Management (TQM) integrating all activities of the
organisation coupled with a customer-centered focus has been taken-up. Suitable
projects have been identified and implemented. Company is nurturing a participative
atmosphere of redressing the grievances of the employees for ensuring peaceful
working environment.

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SWOT ANALYSIS
SWOT analysis is a strategic planning tool used to evaluate the strengths,
weakness, opportunities and threats involved in a project or in a business venture. It
involves specifying the objectives of the business venture or project and identifying the
internal and external factors that are Favourable and unfavourable to achieve the
objectives.
4.1.1 STRENGTH:

Product Line Extension.

Excellent Customer Service.

Strong R & D force.

Innovations in Waste Management and Reusability.

Well Established Network.

Rising Demand-Supply Gap.

Quick Decision through OIIS.

World Bank Assistance.

Capacity doubled within decade.

Largest Bagasse based plant.

Latest Technology Implemented.

Working Continuously on Cost reduction.

Zero Stock of finished goods for the 16 Continuous Year.

New Studies for alternative renewable Raw Materials.

th

4.1.2 WEAKNESS:

Depend Sugar Mill for Bagasse.

Depend on TAFCRN for Pulpwood.

Depend on River Cauvery for water.

Production Break-off due to water Shortage.

Environmental Impact.
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Selective Distribution Channel.

No Promotional Campaign

4.1.3 OPPORTUNITIES:

Raising demand for Paper in Future.

A Produce Cement using mill waste.

Expand Power Generation.

Expand the Clonal Plantation Scheme.

Expand the Methane Gas Production.

Gain a Large Share in Existing Market.

Study on Commercial Suitability of wild Sugarcane.

Alkaline Sizing of Baggasse Based Papers.

4.1.4 THREATS:

Scarcity of Raw Materials.

Deforestation.

Increasing Competition.

Major prolonged economic depression.

Reduce demand due to Paper les office.

Changes in Excise Duty Affect the Price of Paper.

Availability of Low cost Paper in Foreign Market.

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6.1 CONCLUSION
From this report, we able to know about each and every functions of the
department of this organization, it is obvious that it has more efficiency and also able to
survive in this field. The company is now planning to improve its efficiency by having
fully fledged equipment and modern technology to enrich their overall functions. This
organization may use computer which is one of the most wonderful invention of the
centenary will also help this organization to have link with its development in feature.
As for as paper industries are concerned, this industry occupies a major part
among the industries of our economy. This industry alone provides more employment
Opportunities than any other industry. So, government will take all necessary steps to
improve this industry. So that it will be assured that the economy of our country could be
developed.
.

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BIBILIOGRAPHY
Books Referred:
Websites Referred:
www.wikipedia.com
www.google.com
www.tnpl.com

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