Professional Documents
Culture Documents
Packages Limited
Packaging Industry
SUMMARY
Packages limited was established in 1957 as a joint venture of Ali Brothers of Pakistan and Akerlund and Rousing of Sweden, to convert paper and paperboard into packaging for consumer industry. Over the years, Packages has continued to enhance its facilities to meet the growing demand of packaging products. In 1968, with IFC participation, Packages integrated upstream by establishing a pulp and paper mill with a capacity of 24000 tons per year based on waste paper and agricultural by-products. It stands today as one of the biggest manufacturing local companies in Pakistan. Packages offers premium packaging solutions for exceptional value to individuals and businesses. Giants such as Pakistan Tobacco Company and Unilever are among its customers. The company offers various types of paper and board products, corrugated cartons, flexible packaging products and personal hygiene products such as tissues. With a longtime credit rating of AA, growth of sales at 15% and a dedicated and top-quality management team the company has a very bright future and will continue to dominate the industry. In 1968, after going public Packages established a pulp and paper mill having capacity of 24000 tons per year and also enhanced its converting capacity of 24000 tons. With further periodic participation by 1FC and others such as PICIC, DEG and SWEDFUND, etc., the paper and board production capacity increased to 100,000 tons per year by 2003 and conversion capacity to 70,000 tons per year. In 2005, the company tripled its capacity by investing in the new paper mill Bulleh Shah Paper Mill in Kasur.
ii
ACKNOWLEDGEMENTS
We are thankful to Almighty Allah for His unlimited blessings and bounties; for keeping us sane, sound and successful, Our parents for all their support and trust in us, Our Instructor Dr. Nawar Khan, for all his guidance and appreciation, Mr. Muhammad Akram (Industrial Relations Manager), Mr. Hassan Asif (Quality Assurance Manager), Mr. Shahzad Murtaza (In charge Stores and Inventory Department) at Packages Limited Lahore, Saliha Akram at NUST Institute of Environmental Science and Engineering (IESE) for all their support, coordination and time, and all our teachers, friends and colleagues for their help in completion of this report.
iii
TABLE OF CONTENTS
SUMMARY .............................................................................................................................................................. I ACKNOWLEDGEMENTS .......................................................................................................................................... II TABLE OF CONTENTS............................................................................................................................................. III 1 2 INTRODUCTION ............................................................................................................................................. 1 BACKGROUND ............................................................................................................................................... 2 2.1 Over the Years ..............................................................................................................................................2 2.2 Corporate Structure .....................................................................................................................................4 2.3 Products .......................................................................................................................................................5 2.3.1 Paper & Board ..........................................................................................................................................6 2.3.2 Carton Business Unit ................................................................................................................................7 2.3.3 Corruwal Business Unit ............................................................................................................................8 2.3.4 Flexible Business Unit ...............................................................................................................................8 2.3.5 Consumer Products ..................................................................................................................................9 2.4 Organogram ...............................................................................................................................................10 3 PAPER MAKING PROCESS ............................................................................................................................ 11 3.1 Raw Materials ............................................................................................................................................11 3.2 Pulp Making ...............................................................................................................................................12 3.3 Layering/Bonding .......................................................................................................................................12 3.4 Forming ......................................................................................................................................................12 3.5 Coating .......................................................................................................................................................12 3.6 Finishing .....................................................................................................................................................13 3.7 Paperboard.................................................................................................................................................13 3.7.1 Categories ..............................................................................................................................................14 4 PLANNING DEPARTMENT ............................................................................................................................ 15 4.1 Functions ....................................................................................................................................................15 4.1.1 Link between Marketing and Production ...............................................................................................15 4.1.2 Optimizing the Available Capacity .........................................................................................................16 4.1.3 Preparation of Loading Chart ................................................................................................................16 4.1.4 Other Functions......................................................................................................................................16 5 PRODUCTION DEPARTMENT ....................................................................................................................... 18 5.1 Production Procedure ................................................................................................................................19 5.2 Packaging Division ......................................................................................................................................20 5.2.1 Procedure: ..............................................................................................................................................22 5.2.2 FLEXIBLE PACKAGING DIVISION (FP) ......................................................................................................22 5.2.3 Off-Set Printing Department ..................................................................................................................23 5.2.4 Corrugated Department.........................................................................................................................24 5.3 Paper and Board Mill Division ....................................................................................................................27 5.3.1 Production Procedures ...........................................................................................................................28 5.3.2 Pulp Section............................................................................................................................................28 5.3.3 Paper Section .........................................................................................................................................30
iv
6 RESEARCH, DEVELOPMENT & CONTROL DEPARTMENT ............................................................................... 32 6.1 Research .....................................................................................................................................................33 6.2 Development ..............................................................................................................................................33 6.3 Control .......................................................................................................................................................33 6.3.1 TO- DO List of Quality Control ................................................................................................................34 6.3.2 Rubber Section .......................................................................................................................................35 6.3.3 Physical Paper & Polly Packing Section ..................................................................................................35 6.3.4 Pulp Section............................................................................................................................................35 6.3.5 Chemical Section ....................................................................................................................................36 6.3.6 Development Section .............................................................................................................................36 6.3.7 Microbiology Section .............................................................................................................................36 6.3.8 Library ....................................................................................................................................................36 7 8 MANAGEMENT INFORMATION SYSTEM ...................................................................................................... 37 ENVIRONMENTAL POLICY ............................................................................................................................ 39 8.1 8.2 8.3 8.4 9 Recycling Paper ..........................................................................................................................................39 EFFLUENT AND WASTE MANAGEMENT .....................................................................................................39 Water Management ...................................................................................................................................40 Independent Energy House ........................................................................................................................40
RESULTS ...................................................................................................................................................... 41
APPENDIX A ......................................................................................................................................................... 42
1 INTRODUCTION
Packages Limited is the outcome of an idea to develop and build local skill and competence in sophisticated packaging industry based upon indigenous raw material and talent. Established in 1956 as a joint venture between the Ali Group of Pakistan and Akerlund and Rausing of Sweden, Packages Limited provides premium packaging solutions for exceptional value to individuals and businesses. It started its business/production in May 1957, as a private Limited company with a total of about 300 employees. Initially the emphasis was on conversion business and raw material was purchased from outside. Encouraged by the response and confidence reposed by the industry at large, in 1965 it was decided to convert the organization into a Public Limited Company. It is the only packaging facility in Pakistan offering a complete range of packaging solutions including offset printed cartons, shipping containers and flexible packaging materials to individuals and businesses world-wide. Our clientele includes illustrious names such as Unilever and Pakistan Tobacco Company, who have been our customers for over 50 years. It employs over 3000 people and had sales of over US $ 100 million in 2004. Listed on all three stock exchanges in Pakistan, It has maintained a long-time credit rating of AA. Its joint ventures and business alliances with some of the world's biggest names reflect the forward-looking strategy of continuously improving customer value through improvements in productivity. It has always been at the forefront of new developments in packaging research and has pioneered several innovations, including the use of wheat straw as a raw material for paper and board manufacture. The on-site paper and board mill, established in 1968, has constantly increased its production capacity. A new plant with even greater capabilities has also started functioning near Qasur. With more than 50% of the total share in the industry, Packages Limited is the industry leader. It can be thus safely assumed that in this regard, Packages Limited remains unrivalled among all of its competitors like Century Paper Mills, Adamjee Paper & Board Mills Ltd., ABN Packaging International, Arsam Pulp & Paperboard Industries etc.
2 BACKGROUND
2.1 Over the Years
Packaging Limited was born out of a dream to set up in Pakistan industries of excellence based on local raw material and talent. Packages Limited is a leading packaging manufacturing company of Pakistan. It is the sole largest industry in Pakistan serving about 35% needs of the country. Syed Baber Ali Shah, who was the first managing director of Packages Limited went to Sweden in 1954 to negotiate the contract with AB Akerland & Rausing of Sweden. AB Akerland and Rausing had been the leading paper converters in Europe. Pakistanis needed technical collaboration with their Swedish partners. In the beginning, the first problem was the selection of the site. Finally, Lahore was selected due to the following reasons: Easy availability of workers. Easy availability of raw material. Easy transportation all over the country.
A B Akerlund & Rausing packaging company brought machinery and expert technicians while the Ali Family provided the necessary capital, land, labor, local expertise and management. Packages Limited started operating in May 1957 with a paid up capital of Rs. 4.94 million as a joint venture between the Ali group and Akerland & Rausing of Sweden. Initially, it produced cartons for the cigarette, tea, confectionery, soap, pharmaceutical products and other consumer products. These cartons were produced from paper and board supplied from mills in Chittacong, Khulna, Charsadda and Peshawar. However the quality and quantity of paper and board supplied was inadequate. Over the years, the company continued to enhance its facilities to meet the growing demand of packaging products. Additional capital was raised from sponsors, International Finance Corporation and from the public in making the total paid up capital to Rs. 31 million in 1965. As a first step, Packages Limited commissioned its own paper mill in 1968 having production capacity of 24,000 tons of paper & paper board based on waste paper, agricultural waste, wheat straw and kahi grass. As the demand continued to grow, it led the company to expand and by the end of 1998 its annual capacity was increased to 50,000 tons of paper & board and corresponding converting ability.
3 Since 1982, Packages Limited has a joint venture in Tetra Pak Pakistan Limited with Tetra Pak International to manufacture paper for liquid food packaging and to sell Tetra Pak packaging equipment. After Tetra shape, it also introduced brick shape packing. Both shapes are very popular among liquid preservation industries. The main industries covered by Packages Limited are, Tea Industry, Tobacco Industry, Food Industry, Pharmaceutical Industry, Sweets & Confectioneries, Soap Industry, Shoe Industry, Tissue Industry In tetra Pak Pakistan Limited Packages Limited has 45% shares, 6% shares owned by Syed Baber Ali Shah and 49% shares owned by Tetra Pak International. Smart Governance Ethical Behavior Work Environment
Our People
Since 1957, Packages Limited has been producing inks for its own consumption. In 1993, the company agreed to form a joint venture with equity participation from Coates Lorilleux, worlds second largest printing ink manufacturer to produce inks for Packages Limited and the general market. Packages Limited own ink manufacturing facilities now transferred to new company, Coates Lorilleux Pakistan Limited. In July 1994, Coates Lorilleux Pakistan Limited; in which Packages limited has 55% ownership, commenced production and sale of printing inks. Also in 1993, a joint venture agreement was signed with Mitsubishi Corporation of Japan for the manufacturing of polypropylene films at the industrial estate in Hattar, NWFP. This project, Tri-Pack Films Limited, commenced production in June 1995 with equity participation by Packages Limited33%, Mitsubishi Corporation, Altawfeek Company for Investment funds, Saudi Arabia and general Public.
4 Another important service department of Packages Limited is its Power Plant. In 1967 they set up 6 MW power plants, but to ensure a continuous and dependable supply of power for its production lines, Packages Limited has also established its own 10 MW power plant in 1991, the cost of which was 180 million rupees. Packages Limited save a lot of money in this regard. In the field of consumer products, Packages Limited has shown tremendous potential and commendable talent. Consumer Product Division provides 12% share of the total sales. The consumer products of the company are Rose Petal and Tulip tissues. The production of Rose Petal was first introduction of tissue paper industry in Pakistan. Rose Petal and Tulip have more than 80% share of tissue paper industry in Pakistan. Other consumer products are paper Cups, paper Plates, Paper Napkins, Paper Hot Cups and Wet tissues of Rose Petal have been introduced in the market in 1992. Now Packages Limited is exporting its managerial skills & technical expertise to the third world countries like Indonesia, Tanzania, Kuwait, Saudi Arabia, Nigeria, Zambia, Somalia & Russia. It has also started the export of tissues to Iran, Bangladesh, Sri Lanka, Indonesia, United Arab Emirates and Maldives. Packages Limited has a large workshop. This workshop is capable of making, repairing and replacing the damaged parts. The Research, Development & Control Department were also established to ensure the quality and standard of the products. Starting with a work force of 500 workers, now Packages Limited is having 2674 employees. In this regard, a separate Personnel Department is there, to look after the problems of the workers. Today Packages Limited is considered to be a leader in Packaging field in Asia. Packages Limited has completed the balancing, modernization, replacement (BMR) and expansion program, which began in 1994. This has enabled the company to minimize capacity constraints and improve quality to meet local and foreign competition as well as improve its environmental protection facilities.
5 The Packaging Division, which takes materials from the Paper and Board Division and converts customer ideas into finished products The Consumer Products Division, which manufactures off-the-shelf branded consumer products Packages Lanka is a joint venture between Packages Limited and the Print Care Group of Sri Lanka, and DIC Pakistan a joint venture between Packages Limited and Dainippon Ink and Chemicals, Inc. of Japan.
Packaging
Consumer Products
2.3 Products
The different kinds of paper produced at the paper and board division include high gloss writing paper, poster paper, computer paper, fluting paper, and liner for shipping cartons. Most common board varieties include Duplex Board, Bleached Board, Food Grade Board and Card Board. A specialized liquid packaging board is also produced to cater to the need of customers who manufacture and supply aseptic packaging for milk, cream, oil, fruit juices and other food products. In brief: Paper (Writing Paper, Machine Glazed/Special Poster Paper, Fluting Paper, Liner For Shipping Cartons, Corrugating Medium Paper, Wood-free Writing/Printing Paper;) Paperboard (Carton Products , Corrugated Cartons) Packaging Materials (Packaging Films and Laminates ) Consumer Products (Tissue Papers, Personal Hygiene Products) Finished and Semi-finished Inks
2.3.1.1 Paper
Packages Limited produces: high gloss writing paper machine glazed / special poster paper fluting paper liner for shipping cartons corrugating medium paper wood-free writing/printing paper
Paper quality and weight is determined by the client's specific requirements and Packages ensures this is carried out to the exact specifications provided. Paper is available in the following weights:
Type of Paper Test liner Corrugated medium Paper/Fluting Wrapping Paper High gloss writing paper Poster Paper Weight (g/m2) 125-220 120-170 70-90 58-68 40-90
2.3.1.2 Board
Packages Limited manufactures several types of board. Food Board, a basic raw material in liquid food packaging, is being manufactured since 1979 for Tetra Pak Pakistan Limited. This material is used in making aseptic packaging for milk, cream, oil, fruit juices and other perishable food items.
7 Some of the board products are: liquid packaging board food grade board duplex board / chipboard bleached board tobacco board and cardboard liner board Board is available in the following weights:
Type of White Board Bleached Board Duplex Board Cardboard Liquid Packaging Board Poster Paper Weight (g/m2) 195 - 205 150 - 450 160 - 250 150 - 290 40 - 90
8 Clients include Food and Beverages Soap / Detergent Pharmaceuticals Match Electronics Shoe Tobacco Paper Cup
9 odors. Used where colorful package design and preserving product quality are important, such as in the food and pharmaceutical industries, flexographic printing offers economy with quality. Clients are: Soap Tobacco Tea Food Diary Ice-Cream Milk powder Confectionery Shampoo Pesticide Pharmaceutical
Reflecting our core values of exceeding customer expectations through innovation, leadership and teamwork, the Rose Petal and Tulip brands continue to hold over 80% of the domestic market share of the tissue paper market in Pakistan. We also have a leading market share in the away-from-home business: we supply custom-printed boxes, table napkins, coasters and paper cups to institutions such as hotels, fast food chains, restaurants, businesses and the airline industry. Corrugated cartons are of great value to our diverse portfolio of customers for secure transportation of their products to local and international markets. With the commissioning of our corrugated plant in Karachi, we have the capability of producing seven million corrugated cartons to cater to the ever-increasing demand of high quality shipping cartons.
10
2.4 Organogram
Board of Director
Chairman
Advisor
Managing Director
Executive Board
General Manager
Deputy GM
Mill Manager Marketing Manager Consumer Product Manager CSD Manager Commercial Manager Sales & Product Manager Stores & Inventory Manager Group Brand Manager
QC Manager
IR Manager
R&D Manager
IP Manager
11
Hard Wood Bleached Hard Wood Soft Wood Unbleached wood Bleached wood Recycled waste paper Straw Bleached Straw Wheat Straw Pulps Bleached hard wood pulp Bleached straw pulp Unbleached wood pulp Mechanical pulp Waste paper pulp Shredded tetra (BCTP)-Bleached Chemical Thermomechanical Pulp Kraft Unbleached Kraft pulp olympic Unbleached Kraft pulp simpson tacama
Explanation Assist in sizing the paper, making it somewhat water resistant so that inks did not "run" or spread uncontrollably. 0.05 inches (length) Hardwood fibers fill the sheet better and therefore make a smoother paper that is more opaque and better for printing. 0.13 inches (length) e.g. Pine and spruce which have typically long fibers Recycled material is collected and sorted and usually mixed with virgin fibers in order to make new material Straw is pulped to make paper
Pulp when suspended in water becomes dispersed and more pliable and thus can be laid down on a screen to form a sheet of paper.
Shreds of board use in tetra packs Pulp made using some hybrid processes The Kraft process describes a technology for the conversion of wood into wood pulp consisting of almost pure cellulose fibers.
12
3.3 Layering/Bonding
The pulp mixture is diluted with water resulting in very thin slurry (gooey liquid). This dilute slurry is drained of water through a fine mesh/moving screen. Water is also removed through gravity, vacuum action, pressure and heat. A watermark may be impressed into the paper at this stage of the process (a distinguishing mark pressed onto the paper during manufacture; visible when paper is held up to the light.). As water is removed, cellulose fibers bond to form a web of paper (cellulose fibers are fibers that come from plant cell walls and contain glucose, which is a polymer).
3.4 Forming
The moving web is then pressed and dried into a continuous sheet of paper. Most mass produced paper is made using a continuous process to form a reel or web.
3.5 Coating
Coating, the next stage, is the application of a suspension (layer) to the paper surface. It may be performed on the paper machine or on a separate off-machine coater. Coating may be on one or both sides and is followed by drying. Raw paper that contains only pressed and dried pulp is very absorbent (soaks up water, like a sponge) and does not provide a good surface upon which to write or print. Thus a huge variety of additives (chemicals) are employed to add desired properties (characteristics) to the paper. These are applied in a coating called the size. Sizing agents are often polymers designed to provide a better printing surface. The most commonly used type of polymer is starch (a natural polymer), but there are as many types of polymer employed as there are types of paper. Coatings can also be applied to the top layer of paper to improve the printing surface by making it smoother. The texture of raw paper is rough, and so to achieve greater smoothness, coatings
13 consisting of latex or other binders and fillers such as kaolin or calcium carbonate (types of clay) are used. Glossy, silk or matt finish papers such as magazine paper are made in this way. Additionally glossy or textured surfaces can be applied using a process called supercalendering, in which the fresh rolled paper is run through an additional series of rollers to imprint the desired texture. The glossy effect is achieved at the end of the printing process, by adding a clear layer over the printing.
3.6 Finishing
This covers the finishing of pulp, paper and paperboard articles. In this process, the reeled up paper is converted (trimmed, transferred to smaller reels, cut into sheets, etc.) for sale or further processing.
3.7 Paperboard
Paperboard, within the commercial papermaking industry, is simply the term used to describe a thick sheet of paper. Because of this simple definition, there is some confusion in the industry as to what qualifies as paperboard. Thickness (caliper) and bulk are significant aspects in paperboard manufacture, as the end product must be able to withstand the bending forces of packaging, load carrying, shipping etc., while still maintaining their shape. Consequently, these
14 paperboard products are usually comprised of two or more plies to provide the required stiffness. Plies are the term used to describe layers of paper. Within the industry, paperboard is referred to by weight (pounds per square foot or grams per square meter), by thickness (by thousandths of an inch, or 'points' - i.e. 0.009" thick paperboard is also know as 9-point) or by name (food board, corrugating medium, boxboard etc.).
3.7.1 Categories
Paperboard is a generic term, mainly associated with boxboard (multiply board), but can also apply to corrugated board. Corrugated board comprises two main classifications: linerboard and corrugating medium, used almost entirely in the manufacture of shipping cases. Linerboard, which is hard, strong and firm is manufactured in two forms: Kraft liner (produced from Kraft pulp) and recycled liner (made from recycled fibers). Fluting is the wave-like material used as the middle ply in corrugated shipping cases. The combination of linerboard on the outside and fluting in the middle, results in a light and strong finished product, known as corrugated medium. Boxboard may be uniform in substance and quality throughout, or it may emerge from the mill in a single sheet composed of layers made from different types of pulp. Boxboard is of three types: folding, set-up and miscellaneous boxboard. Folding boxboard is made into products such as detergent boxes and milk or juice containers. For containers that will carry products to be ingested, other processes may be required such as the addition of aluminum foil to block out light and oxygen, in order to keep the contents fresh. Set up boxboard is used when a more rigid container is required, for example a jeweler presentation box.
15
4 PLANNING DEPARTMENT
To increase our efficiency, we should plan with excellence. Planning department is one of the most important departments in an organization. Its main functions are to plan huge operations. In Packages the planning department is also playing an important role. The Planning Manager controls the department. The work of planning department is initiated from the industrial marketing department. When the orders are placed to the marketing department, they send out the ISO (Internal Sales Order) to the planning department. An ISO is an internal document on which the information regarding the sales or order is mentioned. Its main function is to transfer the information to the various departments involved. The contents of the ISO provide the following information. 1. Whether it is a new job or old one. 2. Specifications of the routine order i.e. color, size and quantity etc. If it is a new order then this order is first sent to the Art and Camera Department for designing the artwork of the new job. If the job is repeated then there is an approved sample by the customer. The planning department after receiving this ISO along with the sample sends it to the production department.
4.1 Functions
The two main functions of the Planning Department are following:
16
17 To sent daily production reports to the top management Overcoming the complaints of the customers and marketing Department To plan the long term and short term plans for minimizing loss Pursuance of jobs i.e. the current condition of the job To set the production targets for different departments on the basis of invoices Procurement of raw materials To organize the daily program i.e. completion of jobs from shift to shift
18
5 PRODUCTION DEPARTMENT
The role of production department in a manufacturing concern is very important. In Packages the production department is also an important one. The goods for the customers are manufactured according to the desired standards in this department. This department is responsible to plan and organize the allocation of jobs to various machines in a way that their maximum capacity is utilized and that the delivery is given to the customer by stipulated date. The head of the production department is the production manager. The planning department also assists the department. The working procedures are based on week basis i.e. the total no of weeks in a year. The Production Manager looks after the production while the Planning Manager supervises the planning section. The heads of following departments are directly answerable to production manager and they have to present their special problems to him for advice and help: Paper Converting department Off-set Printing Coates Lorilleux (Ink Factory) Art Department Flexible Packaging Division Camera Department Coating Department Cutting & Creasing Department Lamination Department Folding & Gluing Department Dispatch Department Quality Control Department
The Production, Planning and control unit is also directly under the Production Manager and acts as the brain cell for him. Production Manager prepares internal planning of whole Paper & Board Division. It takes into account the total capacity of the machinery, and manpower. It also arranges the resources to attain maximum utilization. The other goal is to reduce the wastage of resources. The planning department acts as a coordinator between the Marketing and production
19 Departments. This is very Important in the sense that if there is no communication between the Marketing and Production Departments, a lot of confusion will be created.
production department who prepare the printing plates. The plates will either go to proofing press or for mass production to offset presses. The order received by the customer to Marketing Department may be: New job Modify the old job Repeating job
In order to develop a new job, to create a new product or to give special suggestions to the customer, sales staff takes help from Development Manager. Development Manager is in touch with all the facilities available at the factory and develops the projects until it is fit for mass production. The new job is first sent to Art and Camera Departments for the art & design to be printed. In case of repeat order, the Production Department will receive the ISO with the sample and the job will be sent to the planning department. Planning department issue a Job Card, as soon as the Job Card is made out, Paper & Board stores arrange material. The immediate requirements are indicated in the Job Card who has to be available in stocks while the long-range requirements are stocked up. Production Manager has to
20 foresee the future requirements. In case of new development, special materials are to be ordered. When substantial orders are expected in a particular line then raw materials will have to be ordered. For example, if there is trend of packaging polyethylene bags then polyethylene granules will have to be bought ahead of time. After Offset Department & Paper Conversion Department (PC) the job run through Cutting and Creasing, Folding and Gluing and is sent out through Dispatch Department. The jobs emanating from Paper Converting & Offset Department go directly to Dispatch Department. One important function of the Dispatch Department is to prepare Dispatch Notes for goods sent out whether by trucks or railway. Production department is further integrated into two divisions namely: 1. Packaging Division 2. Paper and Board Mill
The Paper Converting Department converts the paper into packing material. By Flexo Graphic & Roto Gravure Printing we can get paper or bags in reel forms. It only uses paper and other Polly materials. No board is used in this department. Printing in the Paper Converting Department is several forms: Printing & Conversion of Paper Preparing & Printing Polyethylene bags Preparing Aluminum Foils
21 Fine printing is get from Roto Gravure printing, which is expensive, then Flexo method. The operations are carried out on various machines. Operations include printing polyethylene
extrusion, cutting, creasing, slitting, bag making, waxing etc. The Paper Conversion Department has the following machines. This department split into three sections with the following equipment: SECTION I Two Tea Bag Machines Two Bag Making Machines Four Printing Machines Two, Four Colors Machines One, Six Colors Machines (Only For Polyethylene Bags)
SECTION II Six Slitting Machines One Embossing Machine Two Laminating Machines Four Packing Machines
SECTION III Two Extruder Two Polly Bag Machines One Extruder Laminator Machine One Gumming Machine
22
5.2.1 Procedure:
Out of four Flexo Graphic machines, one is six colors and the rest are four color-printing machines. Hence, in Flexo graphic printing, Packages Limited has the facility to print from two to six colors. In July 1994 they break 1991 record and produce 4455000 meter printed packaging reels. There are six slitting machines, which are used for several kinds of slitting. In Flexo Graphic printing water based ink is used. The machine gets ink for one side and prints it on the other side. There are two polyethylene extruders, which manufacture Polyethylene both at low and high density
Polyethylene from granules, which are mostly imported from the U.S.A, Qatar, U.A.E. All printing machines are imported from Sweden and Germany. The management and operators believe that German machines are very good and their production is also more. The production of six color machines while using Polyethylene is from 1500 to 1700 meters of Polyethylene per hour. Four color printing machine prints about 2400 meters of paper per hour. Total production of these machines per shift is 30000 meters. Packages Limited manufactures and prints high density Polyethylene from 12 grams to 60 grams. And in case of low density Polyethylene it is 20 to 150 grams. In the Polly Section Polyethylene is made while in Waxing Section, the wax machine leaves a film of wax on paper. The Injection Molding machine in the Injection Molding Section makes plastic crates for milk transportation. But lately this section is not working as the demand for them is decreasing. In the Polly Lamination Section, Polly Lamination is done on papers surface to make the surface seasonable and shiny.
This printing is more expensive than stereotype printing. Metallic Cylinder is used in order to get fine printing. This cylinder picks the six color solvent based ink. The materials surface should be 100% glossy and smoother. It processes films whether they are paper, Polly or aluminum foil based, are laminated by containing two or more layers so as t give the required barrier properties against moisture, gases and odors. It produces packaging for soap and confectionery industry. The printing is done in very attractive colors and designs.
The Duplex board is used in this form of printing. The weight of board is 240 to 490 grams. They use imported machines, these machines are made by PLANETA, M.A.N, HIEDLBERG. ROLAND machine is latest and print in five colors. ROLAND AND
In solid board, the board is stitched in the form of boxes. In corrugated, boxes are made by stitching and gluing. This department producing almost 2.5 to 2.8 million boxes per month. The department packaging material provides greater protection against damages and pile ranges of products. For making a box following are the steps: Making three or five layers sheets from paper rolls. Cutting them in sheets according to the size required for package, which is to be produced. Cutting, Creasing, Printing, Folding and gluing these sheets to shape it into the box. Then also bundling these boxes in specifies number.
25
26
27 manually. Last examination of quality control is conducted in this department. From this department, the job is packed in boxes and sent dispatch department.
28 4. Off Set Printing Paper 5. Calendar Paper 6. M.G Brown Wrapping Paper 7. Twist Proof Paper 8. Tissue Paper
29
Wheat straw and cotton lintels are first cut and then cleaned to remove impurities. The material is fed to the digesters after a secondary cleaning of wheat straw.
30
5.3.3.1 PM-1
PM-1 is bought in 1966 from SANO IRON WORKS, JAPAN. It had a capacity of 50 tons per day. It was rebuilt in 1981 with GERMANTECHNOLOGY and its capacity increases to 70 tons per day. This is a multiple board making machine. It can make 2 to 3 ply board. Its width of paper sheet is 2.7 meters, and grammage range is140-490 grams. The types of paper board produced by PM-1: White Duplex Board Corrugating Medium Paper Craft Liner Board White Card Board Kraft Board Chip Board
5.3.3.2 PM-2
This machine was bought in 1984 BELL, Switzerland and has a capacity of 50 tons per day. Packages Limited modified it to increase its capacity to 75 tons per day in1992. It can only make up to two ply board. Its paper width is 1.83 meters, and grammage range is 70-240 grams. The types of paper and board produced: Off-set Printing Paper Wrapping Paper Craft Paper
5.3.3.3 PM-3
It is a MG YANKEE machine bought in 1966 from Switzerland. It was modified in 1982 for the manufacturing of tissue paper and again modified in 1988. Its production capacity is 12 tons per day. Now this machine can make only single ply. It normally manufactures: Glazed Paper Wrapper Paper Brown Draft Poster Paper
5.3.3.4 PM-4
It is the most new Paper machine, which the packages limited, has added in its line of paper machines. PM-4 was installed in 1992 by the technical staff of Packages Limited. It has the capacity to produce 15 tons of paper per day of paper per day. It is an imported ITALIAN machine for manufacturing the tissue paper. It has produced 16 grams tissue paper. The paper & board manufactured by paper machines are wound as big reels. The reels are then sending to Paper Store from where it is provided to the Packaging Division. There it is cut, printed and converted into packaging material used by various industries.
32
Packages Limited maintains the following landmarks with respect to her quality policy: Complies with the ISO 9001 standard 6th company in Pakistan to adopt the ISO series as its quality standard Maintains 57 Quality Improvement Teams in various departments to ensure continuous improvement focus in the organization Nurture Key performance indicators (KPI) concept: Each division in the company sets SMART (specific, measurable, achievable, recordable and time-based) targets for the annual improvement of its key process parameters, reviewed by the management every quarter Maintain a comprehensive set of engineering tools, rules, processes, training materials, guidelines, best practices and other supporting documents to make sure our products comply with every possible customer requirement.
33
6.1 Research
This section is directly responsible to the Production Manager about his research. In Research, work is done with on the idea, experiment is divided into parts and on each part attention is focused and conclusions or suggestions are given. Packages Limited tries to get as many information and technology which is possible and beneficial to the organization. All such information is collected for research. Some time they receive reports of customers problems and complaints from Marketing Department and advice to them through the same channels.
6.2 Development
Development is a continuous process in any organization. A lot of development is the result of feasibility studies, study of new production methods and new products. Packages Limited has a Paper & Board Mill, so it uses largest number of chemicals. The Environment Protection Agency has some standards for reducing pollution. The R, D & Control Department developed new way of reducing pollution and always tries to meet EPA standards.
6.3 Control
Packages Limited R, D & Control Department divides term CONTROL into two areas: Quality Control Process Control
Quality is synonymous with Packages limited. Every package made by Packages Limited guarantees the use of quality materials and processing. This is all due to the strict quality Control Standards, observed at every stage of the production, from raw materials to dispatch Department. This department makes stringent requirements on quality control, which help in working consistently towards attaining better results for customers. To ensure constant quality and improvement this department managed by qualified scientists. Quality Control section has satellite laboratory in every department, which constantly monitor and report. There is on the spot checking and corrective treatment is given to the operators. If the percentage of defective material goes above the permissible limit, the supervisor and machine operator is given a signal to take corrective action. In Process Control, the process of production is carefully monitored. Samples from every
34 department, e.g. Pulp Section, Beater House etc. are taken to quality control department and tested for standard.
R, D & Control Department is divided into different sections for copying different types of problems. The sections are:
35
36 This section also conducts research for new raw materials and to improve the quality and composition of existing raw materials.
6.3.8 Library
The R, D & Control Department has a library also, where a number of books about Packaging Industry are available. The Library provides the best material for related fields and also some on other general topics. Staff of Packages Limited comes there and gets information which may sometimes help in decision making about the problems. The library also keeps the record of all the Research and Development activities for this department. In this section books & material are available on the following topics: Business Administration, Printing, Accounts, Water Treatment, Urdu, Islamic Literature, News Papers, Statistics, Management, Magazines, Economics, Mathematics, Chemistry, Mechanical, Engineering, Packaging and Pulp Industry etc.
37
MIS Department works in collaboration with SYSTEMS LIMITED which maintains the all accounting data of Packages Limited. This job is done through parallel that is the programmers at Packages Limited can also use the facilities of SYSTEMS LIMITED simultaneously. The Computer Department of Packages Limited mostly develops programs in C language. This department has done a lot of programming for the organization. At this time all systems, which are use in the System Department, is developed by its own staff. Normally they do not take enough time to develop a new system. After developing the system they debugged and checked again in order to remove any problem if it exists in the real situation.
38 Earlier this section was using 8088 and 80286 computers but now they have become obsolete due to the rapid development in computer technology. Now they are using MULTI-USER DECSTATION 5000/125. Configuration of this system is given below: CONFIGURATION MODEL NO PM 339-JY DESCRIPTIONS DS 5000/125 SBM 16 MB ULT DECSTATION 5000 Model 125 16 Mb of 4m bit dram, 25 MHz CPU CPU FPU MIPS Clock Speed Cache Memory Memory Capacity R3000 R3010(Moths) 26.8 25 MHz 128KB 8-128 MB
Including Software licenses: ULTRIX, FNS,DECWINDOWS, DECENT COMPAQ MODEL C, MOUSE, UNIFY
The cost of this system is US $ 46000 and additional cost of each terminal. Packages Limited at this time use ON-LINE SYSTEM. Packages also have 32 Personal Computers in different departments to fulfill the requirements. And almost each department has laser printer. The top management believes that this computer section has a great deal to expedite routine jobs at Packages Limited. Company is again updating their system department by purchasing the advance technology SAP under consideration to overcome the Y2K problem.
39
8 Environmental Policy
Packages Limited through it decisions constantly tries to: Minimize its environmental impact, as is economically and practically possible Save raw materials including energy and water, avoid waste Ensure that all its present and future activities are conducted safely, without endangering the health of its employees, its customers and the public Develop plans and procedures and provide resources to successfully implement this policy and for dealing effectively with any emergency Provide environmental, health and safety training to all employees and other relevant persons to enable them to carry out their duties safely without causing harm to themselves, to other individuals and to environment Ensure that all its activities comply with national environmental, health and safety regulations This policy shall be reviewed as and when required for betterment of the same. Packages Limited has the capability of producing 100% recycled paper. Various grades of paper and board (shipping, cartons, newsprint, magazines, and imported waste paper) are collected and then shredded. This is fed to a huge mixer where a controlled percentage of virgin pulp and used paper are mixed together to produce material for recycled paper.
40 the residual sludge and suspended particles. The suspended solids are separated and treated on sludge de-watering equipment and thickened for disposal. The introduction of the new method of using wheat straw as a raw material was a bold step partly aimed at reducing the chemical load of the effluent. An even bolder step was taken with the import of Chemical Recovery Plant in 1997. Black liquor, which poses severe difficulties in the effluent treatment system in any pulp mill, is concentrated in this plant to 58% solids and then incinerated in a waste heat boiler, where organic impurities are destroyed and the steam generated is utilized for evaporating the incoming liquor. The ash, containing inorganic compounds, is dissolved in water to recover any available chemicals.
41
9 Results
Packages Limited has been improving by efforts streamlined through the committee of internal experts to look regularly into issues concerning production, quality, environment, health and safety. The committee is currently involved in the management of fresh water use, effluent management, and control on air emissions, energy conservation and maintenance of health and safety standards in the company. As a result of combined efforts, company has successfully reduced its quantity of water used, as well as its BOD and COD has been reduced significantly. Steam consumption and heat energy consumption in 2003 have both shown a reduction of over 16% each compared to 1999. The electricity use in the same period has gone down by an impressive 25%. These activities have acquired such importance for the company that out of US$ 100 million spent on new processes and technology in the last few years, 20% were spent on environmental issues alone. With similar pace of progress and improvement, Packages will be continue to be the market leader for coming times and a role model for other enterprises, both local and abroad.
42
Appendix A