W&P Paper Manufacturing and Ideas

For an Overall Sustainable Process

A Project Report

Submitted for the fulfillment for the award of the degree of

BACHELOR OF TECHNOLOGY
(Electronics and Communication)
Submitted by

Vasu Garg
(Roll No. – ECE 2498 2k14)

YMCA UNIVERSITY OF SCIENCE AND TECHNOLOGY

FARIDABAD - 121006
Session: 2014-18

Under the guidance of

Mr. Bhagwati Prasad, Dy. HR,
Ballarpur Industries Ltd., a part of Avantha Group
 CERTIFICATE

This is to certify that Mr Vasu Garg has undergone 6 months

training with an aim to understand “P&W Paper Manufacturing
Process” and worked to make the process environmentally more
sustainable to promote the organization’s Corporate Social
Responsibilty.
from 01/06/2017 to 29/12/2017 for the award of the Bachelor of
Technology (Electronics and Communication Engineering), during
the internship semester from BILT, Yamunanagar under my
supervision. The report embodies result of original work and studies
carried out by Student himself and the contents of the report do not
form the basis for the award of any other degree to the candidate or to
anybody else. The report does not contain any thing like designs,
measurements and minute details critical to the organization.

Mr. Bhagwati Prasad

Deputy HR, Ballarpur Industries Ltd.

iii
 CANDIDATE’S DECLARATION

I hereby certify that the work which is being presented in this project report
“P&W Paper Manufacturing and ideas for overall sustainable
process” submitted to ―YMCA University of Science and
Technology, Faridabad, is an authentic record of my own work
carried out in the company ―Ballarpur Industries Ltd, a part of
Avantha Group. The work contained in this thesis has not been
submitted to any other University or Institute.

Vasu Garg
ECE-2498-2k14
B.Tech ECE
YMCA University of Science and Technology
Faridabad-121006

iv
 ACKNOWLEDGEMENT

Every project big or small is successful largely due to the effort of a

number of wonderful people who have always given their valuable advice
or lent a helping hand. I sincerely appreciate the inspiration; support and
guidance of all those people who have been instrumental in making this
project a success.

I would like to extend my sincere and heartfelt obligation towards all the
personages who have helped me in this endeavour. Without their active
guidance, help, cooperation and encouragement, I would not have made
headway in the project.
The internship opportunity with Ballarpur Industries Ltd., a part

of Avantha Group is a great chance for learning and professional

development.

I am ineffably indebted to Mr Bhagwati Prasad and his whole team for

conscientious guidance and encouragement to accomplish this project. As
my project mentor, he helped me with his valuable and helpful feedback
and continued support throughout this project.

I am extremely thankful and pay my gratitude to my faculty Ms. Vinod

Rathore for his valuable guidance and support. I extend my gratitude to
Electronics Department, YMCA University of Science and Technology
and the respected teachers for giving me an opportunity toward on a
research project like this. I perceived this opportunity as a big mile stone
in my career development.

vi
 ABSTRACT

The project name is titled ― W & P paper manufacturing and making

overall process more sustainable. As the name goes the objective of the
project was to get acquainted with the overall process of paper
manufacturing and suggest some ideas which will not only make the
overall process more environment friendly but also more cost effective.

Paper is a material that has been around for about 2000 years. Developedin
China in the first or second century AD, and it’s made by pressing together
the moist fibers of cellulose derived from plants and then dried to result in
flexible sheets. Paper, and the ability to mass product .The properties and
functions of elliptic curves have been studied in it, has resulted in the
development of writing as a means to pass down information through the
ages. This in turn has accelerated information duplication and exchange,
and led to the cultural and technological advancements that we have seen in
the last two millennia (for better or worse).

This project also involves certain ideas given by the student to make the
company achieve its corporate social responsibility. Corporate social
responsibility (CSR) has become one of the standard business practices of
our time. For companies committed to CSR it means kudos and an
enhanced overall reputation – a powerful statement of what they stand for
in an often cynical business world.
The establishment of a CSR strategy (sometimes referred to as a
sustainability strategy) is a crucial component of a company’s
competiveness and something that should be led by the firm itself. This
means having policies and procedures in place which integrate social,
environmental, ethical, human rights or consumer concerns into business
operations and core strategy – all in close collaboration with stakeholders.

vii
As CSR programmes continue to evolve and extend their reach, it may well
become the case that companies find themselves under added pressure to
have their CSR initiatives deliver a strong financial result. If this is indeed
true, many would question whether this financially-orientated approach is
not somewhat at odds with what the core aims of a CSR programme are
supposed to be. “This depends on your timescale,” suggests Mr Webb. “In
three to five years, a good CSR strategy will have delivered more engaged
employees, better access to talent, lower capital constraints and a better
reputation. In the longer term it can deliver serious business innovation and
transformation of the company culture and how the firm sees its role in the
world. Companies attempting this – not yet successfully, but on the way –
include Unilever and Nestle, among others. Two well-known examples of
those that are already there are Interface and Patagonia.”

Others are not convinced that organisations are feeling extra pressure due
to a need to demonstrate stronger financial outcomes in conjunction with
their CSR activities. “Significant pressure to bolster financial outcomes has
always existed and will continue to exist,” says Mr Potts. “There is no
reason why CSR commitments cannot deliver strong financial results, and
it would be folly to expect companies to throw this core corporate objective
out the window altogether.”

The problem arises when companies attempt to measure the financial

results of their CSR policies independent of their other corporate activities.
Rather, CSR policies need to be considered as a core and inseparable
component of the overall service or product offering. Furthermore, the
costs related to CSR should not be expected to demonstrate traceable
financial gains.

viii
Paper making

Contents

Abstract

About the Organization

1. Introduction
1.1 History

1.2. Etymology

1.3. Applications

2. Paper making processes

2.1. Overview

2.2. Manual Paper making

2.3. Industrial paper making

3. Paper manufacturing

3.1. Pulp making

3.1.1. Mechanical pulping

3.1.2. Chemical puulping

3.1.3. Different chemical used

3.1.4. Adantages and disadantages

ix
 3.2. Cleaning

4. Prepration processes

4.1. Defiberisation

4.2. Beating and blending

5. Final processes

5.1. Overall processes

6. Future prospects

7. Enviornmental prospects

8. Corporate social responsibilities

8.1 Ideas suggested

9. Conclusion-A case study

10. References

Project details

ix
ABOUT THE ORGANIZATION

1
 ABOUT THE ORGANIZATION
BALLARPUR INDUSTRIES LTD., PART OF AVANTHA GROUP

AVANTHA GROUP

The Avantha Group is one of India's leading business conglomerates.

The Group has business interests in diverse areas, including pulp and
paper, power transmission and distribution equipment and services, food
processing, farm forestry, chemicals, energy, infrastructure, information
technology (IT) and IT-enabled services.

Group companies include CG Power and Industrial Solutions Limited,

India's largest power equipment company, and Ballarpur Industries
Limited (BILT), India's largest paper manufacturer, both listed on the
Indian stock exchanges.

Across Avantha, good citizenship is a defined objective, with focused

emphasis on education, community development and healthcare.
Led by Founder & Chairman Mr. Gautam Thapar, the Avantha Group
demonstrates strong leadership globally and emerges as a focused
corporate, leveraging its knowledge, leadership and operations to add
lasting value for its stakeholders and investors.

2
HISTORY

The genesis of the Avantha Group lies in the erstwhile Thapar Group,
amongst India's top ten business houses, founded by Lala Karam Chand
Thapar in Calcutta (now Kolkata) more than eighty years ago. India’s
second largest producer of coal prior to coal nationalisation, the Thapar
Group also had interests in sugar, paper, chemicals, textiles, banking,
insurance, and engineering products and services. The Thapar Group went
on to establish some of India’s most respected institutions, including
Oriental Bank of Commerce, Oriental Insurance and Thapar University, to
name a few.

The partition of the Thapar Group’s assets amongst its family members was
completed at the turn of the century. Avantha is a thriving consolidation of
the old conglomerate and Gautam Thapar represents the third generation of
the illustrious business family, the baton having been passed on to him by
his uncle, Mr. L.M. Thapar and his father, Mr. B.M. Thapar.

The group of companies run by Gautam were rebranded as Avantha, and

the new identity launched worldwide on 15th November 2007.
With a rich heritage and a modern outlook, the organisation continues to
evolve and expand. The key drivers of growth remain strategic acquisitions
and exceptional financial structuring to tap opportunities and fuel growth.
Though family owned, the organisation has always been professionally
managed, and lists employee development and leadership training as core
to its business success.

3
VISION

"To Create Lasting Value"

We strive to create lasting value for all our stakeholders through
extraordinary efforts. With integrity, imagination and respect for
individuals.
Lasting to us means timeless - value that will endure, regardless of changes
in our businesses, people, markets or geographies. By constantly setting
and redefining the gold standard in every business we operate in, we will
create enduring value for our employees, customers, partners, shareholders
and society.
For our employees - value in the form of professional growth, through an
enabling work environment, knowledge sharing, implementation of best
practices and growth in their personal life.
For our customers - value through quality products and services,
understanding of their needs and proactively providing solutions, and
contributing to their business growth.
For our partners - value through building mutually beneficial long term
relationships, knowledge sharing and support, and helping them optimise
their business potential.
For our shareholders - value through a high return on investment, a
profitable and sustainable growth platform, and developing the spirit of
enterprise.
For society - value by focusing on the development needs of the
communities we engage with, adopting responsible business practices, and
making a sustained effort to preserve the environment.

4
VALUES

Integrity. Imagination. Individual

Integrity - in both personal and professional relationships

Ho Honouring our commitments to all
stakshareholders

Being open and sincere in all our

dealings

Being accountable and taking ownership

Providing genuine value through our

products and services
Imagination - that drives our actions
Constantly searching for "the new" in all spheres
(be it products, processes, markets, geographies)
Encouraging and implementing original ideas and
"out-of-the-box" thinking
Being agile and responsive to change
Leveraging knowledge and technology to drive
innovation
Individual - a commitment to valuing people
Respect for individuals and recognising their
contribution
Being fair, offering equal opportunity
Encouraging openness and freedom of
expression
Ensuring prompt response to issues and
concerns
Empowering and stimulating employees to
realise their potential

5
BALLARPUR INDUSTRIES LTD.

Ballarpur Industries Limited (BILT) is India’s largest manufacturer of

writing and printing (W&P) paper. BILT’s subsidiaries include Ballarpur
International Graphic Paper Holdings B.V. (BIGPH); BILT Graphic Paper
Products Limited (BGPPL); Sabah Forest Industries (SFI), Malaysia’s
largest pulp and paper company.

In India, the company has six manufacturing units, giving it geographic

coverage over most of the domestic market. The company has a dominant
share of the high-end coated paper segment in India. It accounts for over
53% of the coated wood-free paper market, an impressive 80% of the bond
paper market and nearly 35% of the hi-bright Maplitho market, besides
being India's largest exporter of coated and uncoated paper.

Building on its unmatched paper quality, BILT ventured into the paper-
based office stationery segment. The company markets its stationery
through a well-established network of 350 retail distributors spread over
270 locations. BILT has mega brands such as BILT Royal Executive Bond,
BILT Copy Power, BILT Image Copier and BILT Matrix that have now
become an integral part of office stationery. BILT Ten on Ten notebooks
are targeted at students and are also available with licensed characters such
as Barbie, Spiderman, Winnie the Pooh, Hotwheels, Jungle King and
Hannah Montana. BILT Student Stationery has won ‘Product of the Year’
award for the last three consecutive years. In 2008, BILT forayed into
organised retail through P3 – Paper, Print and Pens – serving both B2C and
B2B clients across India.

In 2005, BILT entered into the tissue and hygiene business with two
brands: Etiquette and Spruce-up. Since then, the company has acquired
Premier Tissues India Limited, the leading player in hygiene tissue
products in the domestic retail market.

6
COMPANY’S COMMITMENTS

Core Values
Honesty
To be principled, straight-forward and fair in all dealings.

Integrity
Maintaining the highest standards of professionalism.

Flexibility
Adapting ourselves to always stay a step ahead of change.

Respect for individual

Giving each person room to contribute and grow.

Respect for knowledge

To acquire and apply leading edge expertise in all aspects of our business.

Team performance
The team comes first; none of us is as good as all of us!

7
 BUSINESS SEGMENTS

Our paper touches our customers’ lives everyday. In more ways than they
even know. Stationery, playing cards, high quality coated paper for
brochures and magazines, currency notes, copier paper. We service these
everyday instances across the length and breadth of the nation with our
wide product portfolio ranging from basic to high-end specialty paper.

 Coated Wood Free Paper

 Uncoated Hi-bright Paper (Maplitho)
 Business Stationery
 Copy Paper
 Speciality & Fine Paper

While these indicate our broad product segments, BILT also continuously
focuses on serving customers with customised, value-added products to suit
specific applications. With the acquisition of Sinar Mas’ Indian operations
(BGPL), BILT has acquired world class coated paper capacities that find
widespread application in the high end of the Indian usage market as well
as developed overseas markets.

8
 COMPANY’S FORESTRY OPERATIONS:

Pulp and paper industry in India, during the last 14-15 years has been
involved in encouraging small land holders to adopt to growing short
rotation, pulpwood species on their marginal or unproductive lands under
buy back assurance and shift its dependence for fibrous raw materials to
non forest sources.

The main species used in agro and farm forestry programmes are Subabool,
Eucalyptus, Acacia, Casuarina and Bamboo.

Under farm forestry model unproductive land is planted only with fast
growing species. This model also provides for growing trees along with
cash crops such as pulses, cotton, soyabean and turmeric etc. for the first
two years. The farmers are supplied good quality plants and are assured
buyback of the wood produce by industry.

COMPANY’S CSR POLICY

BILT Corporate Social Responsibility Policy

"While BILT is responsible to continuously enhance shareholders wealth, it
is also committed to its other stakeholders to conduct its business in a
responsible manner that creates a sustained positive impact on society".
For Bilt being a Socially Responsible Corporate means:
 Using environment friendly and safe processes in production.
 Making sustained effort in preserving the environment.
 Promoting the well being and development of employees and their families
through an inspiring corporate culture that engenders good values.
 Building active and long term partnerships with the communities in which
we operate to significantly improve the condition of the most
disadvantaged amongst them

9
 CHAPTER 1
INTRODUCTION

10
 CHAPTER 1
INTRODUCTION

Paper is simple material. It is essentially a mat held together by the fiber’s

roughness, and can be made from almost any fibrous material like wood or
recycled paper. a thin material produced by pressing together
moist fibres of cellulose pulp derived from wood, rags or grasses, and
drying them into flexible sheets. It is a versatile material with many uses,
including writing, printing, packaging, cleaning, and a number of industrial
and construction processes.
The process for making paper was invented in China in the second century
A.D., and all paper was made one sheet at a time until 1798.

11
The process of making paper has not changed – at least, fundamentally –
since its discovery. But with almost two centuries of improvements and
refinements, modern papermaking is a fascinating, high tech
industry. Wisconsin has led the nation in papermaking for more than 50
years.

The pulp papermaking process is said to have been developed

in China during the early 2nd century CE, possibly as early as the year 105
CE by the Han court eunuch Cai Lun, although the earliest archaeological
fragments of paper derive from the 2nd century BCE in China. The
modern pulp and paper industry is global, with China leading its production
and the United States right behind it.

12
1.1 HISTORY

The oldest known archaeological fragments of the immediate precursor to

modern paper, date to the 2nd century BCE in China. The pulp papermaking
process is ascribed to Cai Lun, a 2nd-century CE Han court eunuch.[2]
Its knowledge and uses spread from China through the Middle
East to medieval Europe in the 13th century, where the first water
powered paper mills were built. Because of paper's introduction to the West
through the city of Baghdad, it was first called bagdatikos. In the 19th
century, industrialization greatly reduced the cost of manufacturing paper. In
1844, the Canadian inventor Charles Fenerty and the German F. G. Keller
independently developed processes for pulping wood fibres.

1.2 ETYMOLOGY

The word "paper" is etymologically derived from Latin papyrus, which

comes from the Greek πάπυρος (papuros), the word for the Cyperus
papyrus plant. Papyrus is a thick, paper-like material produced from the pith
of the Cyperus papyrus plant, which was used in ancient Egypt and
other Mediterranean cultures for writing before the introduction of paper
into the Middle East and Europe. Although the word paper is etymologically
derived from papyrus, the two are produced very differently and the
development of the first is distinct from the development of the second.
Papyrus is a lamination of natural plant fibres, while paper is manufactured
from fibres whose properties have been changed by maceration

13
1.3 APPLICATIONS

Paper can be produced with a wide variety of properties, depending on its

intended use.

 For representing value: paper money, bank note, cheque, security

(see security paper), voucher and ticket
 For storing information: book, notebook, graph paper, magazine,
newspaper, art, zine, letter
 For personal use: diary, note to remind oneself, etc.; for temporary
personal use: scratch paper
 For communication: between individuals and/or groups of people.
 For packaging: corrugated box, paper bag, envelope, Packing &
Wrapping Paper, Paper string, Charta emporetica and wallpaper
 For cleaning: toilet paper, handkerchiefs, paper towels, facial tissue
and cat litter
 For construction: papier-mâché, origami, paper planes, quilling,
paper honeycomb, used as a core material in composite materials,
paper engineering, construction paper and paper clothing
 For other uses: emery paper, sandpaper, blotting paper, litmus
paper, universal indicator paper, paper chromatography, electrical
insulation paper (see also dielectric and permittivity) and filter
paper.

It is estimated that paper-based storage solutions captured 0.33% of the

total in 1986 and only 0.007% in 2007, even though in absolute terms, the
world's capacity to store information on paper increased from 8.7 to 19.4
petabytes.[14] It is estimated that in 1986 paper-based postal letters
represented less than 0.05% of the world's telecommunication capacity,
with sharply decreasing tendency after the massive introduction of digital
technologies.

14
CHAPTER 2
PAPER MAKING
PROCESSES

15
 CHAPTER 2
PAPER MAKING PROCESSES

2.1 OVERVIEW

The art, science, and technology of papermaking addresses the methods,

equipment, and materials used to make paper and cardboard, these being
used widely for printing, writing, and packaging, among many other
purposes and useful products. Today almost all paper is manufactured
using industrial machinery, while handmade paper survives as a specialized
craft and a medium for artistic expression.

In papermaking, a dilute suspension consisting mostly of separate cellulose

fibres in water is drained through a sieve-like screen, so that a mat of
randomly interwoven fibres is laid down. Water is further removed from
this sheet by pressing, sometimes aided by suction or vacuum, or heating.
Once dry, a generally flat, uniform and strong sheet of paper is achieved.

Before the invention and current widespread adoption of automated

machinery, all paper was made by hand, formed or laid one sheet at a time
by specialized laborers. Even today those who make paper by hand use
tools and technologies quite similar to those existing hundreds of years ago,
as originally developed in China and Asia, or those further modified in
Europe. Handmade paper is still appreciated for its distinctive uniqueness
and the skilled craft involved in making each sheet, in contrast with the
higher degree of uniformity and perfection at lower prices achieved among
industrial products.

16
 2.2 MANUAL PAPERMAKING

The method of manual papermaking changed very little over time, despite
advances in technologies. The process of manufacturing handmade paper
can be generalized into five steps:

1. Separating the useful fibre from the rest of raw materials. (e.g. cellulose
from wood, cotton, etc.)
2. Beating down the fibre into pulp
3. Adjusting the colour, mechanical, chemical, biological, and other properties
of the paper by adding special chemical premixes
4. Screening the resulting solution
5. Pressing and drying to get the actual paper

Screening the fibre involves using a mesh made from non-corroding and
inert material, such as aluminium, which is stretched in a wooden frame
similar to that of a window. The size of the paper is governed by the size of
the frame. This tool is then completely submerged in the solution vertically
and drawn out horizontally to ensure a uniform coating of the wire mesh.
17
This stack of wet mats is then pressed in a hydraulic press very gently to
ensure the fibre does not squeeze out. The fairly damp fibre is then dried
using a variety of methods, such as vacuum drying or simply air drying.
Sometimes, the individual sheet is rolled to flatten, harden, and refine the
surface. Finally, the paper is then cut to the desired shape or the standard
shape (A4, letter, legal, etc.) and packed.

2.3 INDUSTRIAL PAPERMAKING

A modern paper mill is divided into several sections, roughly

corresponding to the processes involved in making handmade paper. Pulp
is refined and mixed in water with other additives to make a pulp slurry.
The head-box of the paper machine (Fourdrinier machine) distributes the
slurry onto a moving continuous screen, water drains from the slurry (by
gravity or under vacuum), the wet paper sheet goes through presses and
dries, and finally rolls into large rolls. The outcome often weighs several
tons.

Another type of paper machine makes use of a cylinder mould that rotates
while partially immersed in a vat of dilute pulp. The pulp is picked up by
the wire and covers the mould as it rises out of the vat. A couch roller is
pressed against the mould to smooth out the pulp, and picks the wet sheet
off the mould.

18
 CHAPTER 3
PAPER MANUFACTURING
PROCESS

19
 CHAPTER 3
PAPER MANUFACTURING PROCESS

3.1 PULP MAKING PROCESS

Manufacturing of pulp starts with raw material preparation (Smook 1992a

; Biermann 1996a ) . This includes debarking (when wood is used as raw
material), chipping, and other processes such as depithing (for example,
when bagasse is used as the raw material). Cellulosic pulp is manufactured
from the raw materials, using chemical and mechanical means. The
manufacture of pulp for paper and cardboard employs mechanical
(including thermomechanical), chemimechanical, and chemical methods.

3.1.1 MECHANICAL PULPING

Mechanical pulping separates fi bers from each other by mechanical
energy applied to the wood matrix causing the gradual break of the bonds
between the fi bers and the release of fi ber bundles, single fi bers, and fi
ber fragments (Smook 1992b ; Biermann 1996b ) . It is the mixture of fi
bers and fi ber fragments that gives mechanical pulp its favorable printing
properties. In the mechanical pulping, the objective is to maintain the main
part of the lignin in order to achieve high yield with acceptable strength
properties and brightness. Mechanical pulps have a low resistance to aging
which results in a tendency to discolor. The main processes are Stone
Groundwood Pulping (SGW), Pressure Groundwood Pulping (PGW),
Thermo-Mechanical Pulping (TMP), or Chemi-Thermo-Mechanical
Pulping (CTMP). The groundwood pulping process grinds wood into pulp.
Usually this involves taking a log and pressing it against a rotating surface
to grind off small pieces. The groundwood pulp is then often cooked to
soften it. This pulp is used in newsprint and other low cost book grades
where it contributes bulk, opacity, and compressibility. Groundwood pulp
is economical since all the wood is used; however, it contains impurities
that can cause discoloration and weakening of the paper.

20
3.1.2 CHEMICAL PULPING

Chemical pulping is used on most papers produced commercially in

the world today (Smook 1992b ; Biermann 1996b ) . Traditionally, this has
involved a full chemical treatment in which the objective is to remove
noncellulose wood components leaving intact the cellulose fi bers. In
practice, separation of the components is never completely realized. Yet
satisfactory compromises are reached in the processes which yields
somewhere between 45 and 55% of the wood mass. Chemical pulps are
made by cooking (digesting) the raw materials, using the kraft (sulfate) and
sulfi te processes. The kraft (sulfate) process is the most dominating
chemical pulping process worldwide. The term “sulfate” is derived from
the makeup chemical sodium sulfate, which is added in the recovery cycle
to compensate for chemical losses. In the kraft pulp process the active
cooking chemicals (white liquor) are sodium hydroxide (NaOH) and
sodium sulfi de (Na 2 S). Kraft process is applicable to all types of wood
species but its chemistry carries with it an inherent potential problem of
malodorous compounds. Kraft pulp possesses superior pulp strength
properties in comparison to sulphite pulp. Kraft processes produce a variety
of pulps used mainly for packaging and high-strength papers and board.
Chemical recovery is an essential part of the pulp production process (Tran
2007 ; Vakkilainen 2000 ; Bajpai 2008 ; Biermann 1996c ) . Half of the
wood raw material is utilized as chemical pulp fi ber. The other half is
utilized as fuel for electricity and heat generation. In fact, a pulp mill has
two main lines. Wood is turned into pulp on the fi ber line. Energy is
produced on the chemical recovery line from the wood material cooked in
the liquor; the cooking chemicals are recovered for reuse. In the chemical
recovery line, the black liquor is evaporated and combusted in a recovery
boiler, and the energy content of the dissolved wood material is recovered
as steam and electricity. The chemical pulping process generates more
energy than it uses. A pulp mill generates energy for its own use and energy
to sell.

21
3.1.3 DIFFERENT CHEMICALS USED

Different processes use different chemicals to separate lignin. Sulfi te

process uses different chemicals to attack and remove lignin. The sulphite
process is characterized by its high flexibility compared to the kraft
process, which is a very uniform method, which can be carried out only
with highly alkaline cooking liquor. In principle, the entire pH range can be
used for sulphite pulping by changing the dosage and composition of the
chemicals.
Thus, the use of sulphite pulping permits the production of many different
types and qualities of pulps for a broad range of applications. The sulphite
process can be distinguished according to the pH adjusted into different
types of pulping. The main sulphite pulping processes are Acid (bi)sulphite,
Bisulphite (Magnefi te), Neutral sulphite (NSSC), and Alkaline sulphite.

3.1.4 ADVANTAGES AND DISADVANTGES

Each pulping process has its advantages and disadvantages (Smook 1992b ;
Biermann 1996b ) . The major advantage of mechanical pulping is its high
yield of fi bers up to 90%. Chemical pulping yields approximately 50% but
offers higher strength properties and the fi bers are more easily breached
because the mechanical pulping process does not remove lignin. Even with
subsequent bleaching, these fi bers are susceptible to yellowing. This is the
reason that paper grades containing high 10 2 Brief Description of the Pulp
and Paper Making Process quantities of mechanical pulp fi ber such as
newsprint discolor quickly, especially when exposed to sunlight.

22
3.2 CLEANING

The fibers are then meshed, screened and dried through an ECF process and
the subsequent pulp produced are then baled or supplied in slush form for
paper making.

Elemental Chlorine-Free (ECF) bleaching -- based on chlorine dioxide -- is

the superior choice for pulp and paper manufacture. The science, a proven
environmental track record, and strong market demand demonstrate that
ECF is without rival in terms of pollution prevention, resource
conservation, and product quality.

Chemistry While chlorine dioxide has "chlorine" in its name, its chemistry
is very different from that of chlorine gas...
• Chlorine gas (Cl2) is made up of two chlorine atoms. Chlorine dioxide
(ClO2) is composed of one chlorine atom and two oxygen atoms. It is
roughly 50 percent oxygen by atomic weight.
• During the pulp bleaching process, chlorine tends to combine with lignin
(the substance that holds the wood fibers together) to create chlorinated
organics that end up in mill waste water.

23
In contrast, chlorine dioxide typically breaks apart the lignin, leaving
behind organic compounds that are water soluble and very similar to those
occurring naturally in the environment

24
3.2.1 ECF Vs TCF

Following the abandonment of chlorine as a bleaching agent due to

environmental considerations, two technologies were developed. The first
is Elemental Chlorine Free (ECF) and the second is Total Chlorine Free
(TCF). The distinguishing factor between the two processes is the use of
chlorine dioxide, which is used in ECF but not TCF. To compensate for the
lack of chlorine dioxide, TCF will either add higher dosages of peroxide, or
supplement the process with ozone. (Learn more in this research
paper Environmental systems analysis of alternative bleaching sequences
with focus on carbon footprint by Pia Jour, Karin Halldén and Eva
Wackerberg)

In 2012, ECF pulp constituted 93% of the world share of bleached

chemical pulp market. TCF, although decreasing slightly in market share,
has remained at approximately 5% of the bleached chemical pulp market.
Initially TCF appeared to hold promise as an alternative to ECF with
respect to the generation of environmentally harmful substances. However,
several studies have shown no significant difference between the two
technologies when best available techniques is used. No measureable levels
of dioxins are present with either ECF or TCF. TCF's problems with
weaker fiber strength, lower brightness potential, lower yield and higher
energy requirements have further eroded its promise as a successor to ECF.

25
 CHAPTER 4
PREPARATION PROCESS

26
4.1 DEFIBERIZATION

This is a process to finally prepare and send out raw materials for
papermaking. Specifically, this process consists of defiberization of
purchased pulp and broke, beating of raw materials, blending of raw
materials, addition of fillers, sizers, and chemicals, dust removal, and de-
aeration. Low consistency pulpers are used for defiberization of purchased
pulp and broke, and cleaners and screens are used for dust removal. Pulpers
use rotating blades in the tank to generate a vortex in the water to carry out
defiberization. Low consistency pulpers carry out defiberization in
concentrations of 3.5 - 5.5 percent. Cleaners and screens use the same
principle and similar structures as those described in the “mechanical pulp
manufacturing process” paragraph.

4.2 BEATING AND BLENDING

The following is a description of the beating of raw materials, blending of
raw materials, and the addition of fillers, sizes, and chemicals. (1) Beating
of raw materials Fundamental factors of beating are to swell fibers, increase
the flexibility and surface area of fibers, fibrillate (making fibers fibril), and
cut (trimming fibers) by beating fibers with a disk refiner, etc. The more
fibers are beaten, the more their water retention is improved and sheet
formation is facilitated. (2) Blending of raw materials Important factors of
blending raw materials are to recycle broke generated during the
papermaking, coating, and finishing processes and to blend raw materials
and recovered white water released outside from preparation and
papermaking processes. Keeping these procedures reduces raw materials
loss as much as possible, improves retention, and reduces wastewater
treatment load. White water refers to the water that contains flour (minute
fibers), which is drained from the wire part of paper machines at the
papermaking process, at a concentration of about 0.5 percent. Broke
generated at the dryer part of paper machines, coating, and finishing
processes is defibrated by pulpers.

27
Raw materials are beaten individually according to the tree species, mixed
with other different types of pulp, such as wastepaper pulp or broke, and
are added to recovered white water in the mixer. Specified quantities of
different types of pulp are blended and stored in a mixing chest. (3)
Addition of fillers, sizing agents, and chemicals The main purpose of fillers
is to improve opacity, brightness, smoothness, and ink receptivity by filling
the void between fibers to improve printability and appearance after
printing. They are also effective at making paper thick, tight, and soft.
Although kaolin and talc have been traditionally used as fillers, recently an
increasing amount of calcium carbonate is used due to the increase of
neutralized paper. Sizing treatment is designed to prevent ink feathering on
the paper for printing 8 or writing, or to add water resistance to wrapping
paper and board liners for corrugated fiberboard due to their content and
usage conditions. Although rosin (pine resin) and its fixing agent-
aluminium sulfate-have been used as sizing agents (acidic sizing
papermaking method), the neutral sizing papermaking method uses calcium
carbonate as the filler and alkylketene dimers or alkenyl succinic anhydride
as sizing agents. Sizing agents that give water-resistance to paper include
melamine resin, urea formaldehyde resin and water-soluble thermosetting
resins such as polyethylenimine. Other chemicals, such as retention aids
(that reduce retention loss with fixing flour), strengthening agents for paper
(that improve sheet strength of paper by increasing the number of fiber
bonding points), slime control agent (that keeps slime from developing by
sterilizing microorganisms), antifoaming agent, and dyes, etc., are added as
required.

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CHAPTER5

CHAPTER 5
FINAL PROCESS

29
 CHAPTER 5
PAPERMAKING PROCESS

5.1 OVERALL PROCESS

The papermaking process is to dilute and disperse the prepared materials,
or paper stock, spray the paper stock on wire cloth to form a paper sheet,
and drain water from the sheet and dry it. A paper machine consists of a
paper machine mainframe and auxiliary equipment. The paper machine
mainframe consists of a stock inlet, wire part, press part, dryer part, size
press, calender, and reel along the flow of materials. The auxiliary
equipment consists of a driving unit, approach pipes that supply raw
materials and circulate white water, a vacuum system that drains water
from the wire part and press part, a drainage system that supplies and
recycles steam for the dryer bank, an air system that circulates and uses air
for drying and recovers waste heat, etc. Papermaking machines are roughly
classified into the Fourdrinier machine and the cylinder machine according
to the type of wire part, and the multiple cylinder dryer and the Yankee
dryer according to the type of dryer part. (1) Dewatering process Materials
with which pulp, filler, and sizing agent, etc., are blended are put in a
machine chest as mother stock, diluted with white water in the system, and
jetted out on a wire net through the stock inlet. The Fourdrinier machine
uses a continuous wire net. The mother stock is sprayed or dropped onto
the moving wire net. After the water is drained, a paper sheet is formed on
the wire net. Table rolls and hydrofoils are arranged in the wire net part to
optimize drainage kinetics for sheet formation. Paper stock is first dried on
the wire net by suction generated by the rotation of table rolls or contact
between the hydrofoil and wire net, and its concentration becomes about 20
percent where the sheet leaves at the end of the wire net part. A cylinder
mold rotates in the vat of the cylinder type paper machine, and mother
stock forms a paper sheet on the net of the cylinder mold as it rotates. The
wet paper sheet (paper on the paper machine) contains too much water and
its tensile strength is small when it is away from the wire net part. The
press part compresses and drains it to form a stronger sheet.

30
A wet paper sheet with high moisture content breaks under high pressure,
therefore the concentration of the wet paper sheet is raised from 20 percent
(moisture content: 80 percent) to 40 - 50 percent (moisture content: 60 - 50
percent) by gradually increasing pressure by several press rolls. White
water drained in the wire net part is circulated within the system, but white
water drained at the press part is sent to a wastewater treatment process. (2)
Drying process After the press part, the wet paper sheet is heated with the
dryer to a moisture content level of 6 - 10 percent. Usually at the dryer part,
there are several tens of cast-iron cylinders measuring 1.2 - 1.8 m in
diameter and they hold the wet paper sheet with canvas and contact with
the surface of the cylinders evaporates the paper 10 sheet’s moisture. The
Yankee dryer with one cylinder that measures 2.4 - 4.5 m in diameter is
used to produce glazed paper. If the used chemicals are volatile, they may
be released to the air at the dryer part. (3) Size press coating process The
size press machine applies starch to paper in the middle of the dryer process
in order to give water resistance and surface strength to the paper. The size
press was popularized with the progress of offset printing. Typical models
of size press coater are the inclined type and the gate roll type. The
inclined-type size press coater has a so-called dip coating structure with
two inclined rolls that contact each other with pigment supplied between
the rolls. Paper passes through the rolls. Although the structure is simple,
concentration of the pigment is as low as 4 - 5 percent. The gate roll coater
has a structure consisting of several rolls and applies pigment at a
concentration of 10 - 20 percent with the same function of coating
machines. (4) Calendering and reel process A calender consists of several
steel rolls, or calenders, that rub the surface of the paper sent from the dryer
part, to smooth and gloss it. Friction between calender rolls and paper
generates heat, which may cause the diameter of rolls to slightly change in
any direction. Therefore the calender has a device that blows out cool air to
prevent thermal expansion of rolls and to finish a uniform thickness of
paper. The paper sent out of the calender is wound on a reel and shipped as
a product after finishing.

31
for ECC and RSA is comparable . Thus, there is a computational advantage to
using ECC with a shorter key length than a comparably secure RSA.

32
 CHAPTER 6
FUTURE PROSPECTS

33
 CHAPTER 6

Some manufacturers have started using a new, significantly more

environmentally friendly alternative to expanded plastic packaging. Made
out of paper, and known commercially as PaperFoam, the new packaging
has mechanical properties very similar to those of some expanded plastic
packaging, but is biodegradable and can also be recycled with ordinary
paper.[30]

With increasing environmental concerns about synthetic coatings (such

as PFOA) and the higher prices of hydrocarbon based petrochemicals, there
is a focus on zein (corn protein) as a coating for paper in high grease
applications such as popcorn bags.
Also, synthetics such as Tyvek and Teslin have been introduced as printing
media as a more durable material than paper.

34
 CHAPTER 7
ENVIRONMENTAL IMPACTS

35
 CHAPTER 7
ENVIRONMENTAL IMPACTS

The production and use of paper has a number of adverse effects on the
environment.
Worldwide consumption of paper has risen by 400% in the past 40
years leading to increase in deforestation, with 35% of harvested trees
being used for paper manufacture. Most paper companies also plant trees to
help regrow forests. Logging of old growth forests accounts for less than
10% of wood pulp but is one of the most controversial issues.
Paper waste accounts for up to 40% of total waste produced in the United
States each year, which adds up to 71.6 million tons of paper waste per year
in the United States alone. The average office worker in the US prints 31
pages every day. Americans also use in the order of 16 billion paper
cups per year.
Conventional bleaching of wood pulp using elemental chlorine produces
and releases into the environment large amounts of chlorinated organic
compounds, including chlorinated dioxins.[28] Dioxins are recognized as a
persistent environmental pollutant, regulated internationally by
the Stockholm Convention on Persistent Organic Pollutants. Dioxins are
highly toxic, and health effects on humans include reproductive,
developmental, immune and hormonal problems. They are known to be
carcinogenic. Over 90% of human exposure is through food, primarily
meat, dairy, fish and shellfish, as dioxins accumulate in the food chain in
the fatty tissue of animals

36
 CHAPTER 8
CORPORATE SOCIAL
RESPONSIBILITY

37
 CHAPTER 8
CORPORATE SOCIAL RESPONSIBILITY

Corporate social responsibility (CSR, also called corporate

conscience, corporate citizenship or responsible business) is a form
of corporate self-regulation integrated into a business model. CSR policy
functions as a self-regulatory mechanism whereby a business monitors and
ensures its active compliance with the spirit of the law, ethical standards
and national or international norms.
With some models, a firm's implementation of CSR goes beyond
compliance and statutory requirements, which engages in "actions that
appear to further some social good, beyond the interests of the firm and that
which is required by law". The binary choice between 'complying' with the
law and 'going beyond' the law must be qualified with some nuance. In
many areas such as environmental or labor regulations, employers can
choose to comply with the law, to go beyond the law, but they can also
choose to not comply with the law, such as when they deliberately ignore
gender equality or the mandate to hire disabled workers. There must be a
recognition that many so-called 'hard' laws are also 'weak' laws, weak in the
sense that they are poorly enforced, with no or little control or no or few
sanctions in case of non-compliance. 'Weak' law must not be confused
with soft law. The aim is to increase long-term profits and shareholder trust
through positive public relations and high ethical standards to reduce
business and legal risk by taking responsibility for corporate actions. CSR
strategies encourage the company to make a positive impact on the
environment and stakeholders including consumers, employees, investors,
communities, and others.

38
8.1 IDEAS SUGGESTED

Water treatment :- while bleaching or before the pulp reaches to the roller
to become a thin sheet, the whole process requires a lot of water. I have
suggested the firm to use the water which is now going on to sewage for
the process again meeting the company its corporate social responsibility
targets. Growing water scarcity and heightened awareness associated with
water conservation are prompting more industrial manufacturers to explore
water recycling within facilities - a strategy which also reduces wastewater
effluent volumes.
Water recycling is an attractive proposition for industries such as P&P that
withdraw large volumes of water or have highly polluted waste streams and
are subject to increasing charges for disposal, according to a market report
by independent research and advisory firm Lux Research, which evaluated
water usage and industrial water treatment across six of the top water users
among manufacturing industries.
In Demystifying the Industrial Water Market, Lux Research found that
recycling of water within the P&P industry is an increasingly common
solution because it allows facilities to reuse water and also recover excess
pulp fibers that have escaped in the wastewater, providing the industry with
a high economic incentive to recycle its waste streams.
"Membrane technologies such as microfiltration, ultrafiltration, and
nanofiltration are the most effective strategies for treating water to a level
where it can be utilized in the beginning of a process," said Brent Giles, a
senior analyst at Lux Research.
"Additionally, employing a careful choice of the chemicals added to
treatment water also makes recycling easier," he added. "Using ozone
instead of chlorine, for instance, eliminates long-term residual and makes
the wastewater less caustic to the membranes."

39
 CHAPTER 9
CONCLUSION: A CASE
STUDY

40
 CHAPTER 8
PAPER MAKING IN NEW HAMPSHIRE
The story of papermaking in New Hampshire exemplifies both the
beneficial and detrimental environmental and economic aspects of the
industry as discussed above and provides insight into the future of an
industry that has been a prevalent part of that state’s economy for centuries.
Pioneers started settling along the Upper Androscoggin River in the North
Country of New Hampshire in the 1780s. Early residents of the area
focused on agriculture to sustain themselves until the 1820s when the
state's natural resources – trees and rivers – gave birth to the logging
industry in the region. With an abundance of tree varieties and demand for
wood products, the timber industry in the North Country flourished. The
Androscoggin and Magalloway Rivers were keys to the success of the
logging industry, providing transport of timber until trains arrived in
Gorham (1851) and Berlin (1855). (The last long-log river drive occurred
in 1937, and using rivers for the transport of any timber ceased in the 1960s
when International Paper Company and Brown Company began using
alternative means to move pulpwood for their papermaking operations.)
Loggers ha
vested white pine and red spruce for building materials, hemlock for
tanning, tamarack for shipbuilding, white cedar for shingles and balsam fir
for boxes. In the 1870s, the pulp and paper industry, which used smaller
spruce trees, was established in the region as well. The paper industry grew
throughout the early 20th century, and consolidation of paper
manufacturers increased industry control and influence in the region. The
result was an increase in production and continued deforestation. By the
early 1900s, little virgin forest remained in the Androscoggin River valley
due to the aggressive acquisition of land and control of the tree harvest by
Brown Mills Company and International Paper Company. Fortunately, due
to past experiences and innovations in timber harvesting, sustainable forest
management principles were established.

41
A subsequent benefit of the regrowth of the forests was the return of many
animal species that lost their habitat during the 1800s when clearcutting the
forests was at its peak. Although deforestation is no longer a concern in
New Hampshire, the wider environmental impact of papermaking proved
disastrous to the region.
For example, the Androscoggin River was one of the most polluted rivers
in the US through the late 1970s due to the effluence created by paper
mills. The fumes created by the effluent were said to have peeled the paint
off houses. Additionally, aquatic life was not sustainable, the rivers in the
region contained white foam, and the water’s color was dark and murky.
Due to the passage of the Clean Water Act in 1972, the North Country
rivers have made a dramatic recovery. And as will be discussed later, the
decline of the papermaking industry in NH has led to further improvement
of the environment, as have other government regulations. The forest-based
industries are not nearly as large as they once were, and economies in the
region are continually shifting to service industries such as tourism and
healthcare. In 2001, New Hampshire’s papermaking industry employed
only 10,000 people. In 2004, it generated $333 million in revenue, but the
forecast for employment in the papermaking and timber industries is bleak.
(“Affected Environment,” Regional and Local Demographics, 2010 US
Fish and Wildlife Service). At this writing, the future of the last paper mill
in the North Country of New Hampshire, Fraser Papers, is unknown
because a buyer may purchase the mill which closed down on October 13,
2010. The deal has not been completed, nor has a plan to reopen the mill
been provided. The closing of Fraser Paper may in fact prove to be the end
of the centuriesold papermaking industry for the North Country of New
Hampshire.

42
 CHAPTER 10
REFERENCES

1. McKenzie, Bruce G. (1989). The Hammerhill guide to desktop publishing in

business. Hammerhill. p. 144.

2. "Density of paper and paperboard". PaperOnWeb. Retrieved 31

October 2007

3. Clark, James d'A. (1985). Pulp Technology and Treatment for Paper (2nd
ed.). San Francisco: Miller Freeman Publications. ISBN 0-87930-164-3.

4. papyrus, on Oxford Dictionaries

5. Burns, Robert I. (1996). "Paper comes to the West, 800–1400". In Lindgren,

Uta. Europäische Technik im Mittelalter. 800 bis 1400. Tradition und Innovation (4th
ed.). Berlin: Gebr. Mann Verlag. pp. 413–422. ISBN 3-7861-1748-9.

6. Westerlund Leslie C. "Dictionary of Papermaking" ISBN 1-876141-24-7, 2005; WES

7. Westerlund Leslie. C. "How to Make a Papermaking Couching L'Transfer

Curve" ISBN 1-876141-49-2, 2007; WES

8. Forest Products Laboratory (U.S.) (1953). “American woods for papermaking.” U.S.
Dept. of Agriculture, Forest Service, Forest Products Laboratory

9. Herbert Holik "Handbook of paper and board", Wiley-VCH, 2006, ISBN 3-527-
30997-7, ISBN 978-3-527-30997-9

43
PROJECT DETAILS

Student Details
Student Name Vasu
Roll No ECE 2498 2K14
Email Address Vasugarg2197@gmail.com Phone No (M) 9416844103
Project Details
Project Title W&P Paper manufacturing and ideas for an overall sustainable process
Project Duration 6 Months Date of reporting 1st June 2017
Organization Details
Organization Name Ballarpur Industries Ltd.
BILT, workshop road, near Jagadhari-
Full postal address Yamunanagar railway station, Yamunanagar
with pin code
Website address https://www.bilt.com
Supervisor Details
Supervisor Name Bhagwati Prasad
Designation Deputy Managar
Bhagwati.prasad1@bilt.co
Email address m Phone No (M) 9812302548
Internal Guide Details
Faculty Name Ms Vinod Rathore
Full contact address Electronics Department, YMCA University of Science and technology,
with pin code Faridabad 121006

44