PACKAGING PAPER (KRAFT PAPER) FROM AGRICULTURAL RESIDUE (BAGASSE/WHEAT HUSK)
[EIRI/EDPR/4383] J.C.: 2576ETB, 2577INR
INTRODUCTION
Paper form a commodity of prime importance to day from the parts of view of mass communication, education, and industrial and economic growth. Agricultural residues, such as bagasse, rice husk, wheat husk jute sticks, grasses, etc are fast becoming popular materials for paper making considerable attention is being given to the utilization of various agricultural by products for preparing pulp for paper manufacturing efforts are being made in this direction.
Bagasse is used for each of the four main paper categories, namely packaging and boxes, printing, writing and photocopier paper, tissues, and newsprint. Both chemical and mechanical pulping processes are used, and these processes are described. This chapter focuses on the considerations for bagasse-based pulp and paper manufacture with only a broad overview of the general wood-based process. Depithing is used to improve pulp drainage in the pulp washers and at the paper machine, reduce cooking chemical usage, reduce foaming, reduce costs for handling and storage, reduce dirt count in the paper, improve tensile properties and improve black liquor quality.
Wheat straw pulp plays an indispensable role in the paper and pulp industry. There are some restrictive factors that limit the development of wheat straw pulp. Firstly, the collection and transportation of raw materials; secondly, the straw pulp mill usually has a small scale, poor technology, and paper pulper machines, which result in low-quality pulp and market competition. Last but not least, serious environmental pollution caused by wheat straw pulp production. With the development of straw pulping technology, the straw pulp will have a bright future in the industry.
Paper production requires a disintegration of the bulky fibrous material to individual or small agglomerate fibres. This is called pulping. The ideal fibre for high grade paper should be long, high in cellulose content.
The evolution of the packaging industry across the globe acts as one of the major factors driving the growth of kraft paper market. The increase in demand for sustainable and recyclable material from packaging and various other end-use industries, and advancements in packaging and wrapping applications accelerate the market growth. The rise in demand for more environment friendly and effective packaging materials and solutions from end-use industries such as foods & beverage, building and construction, automotive, pharmaceuticals, cosmetics & personal care, aerospace, and electronics, and rise in consciousness regarding environment among population further influence the market. Additionally, change in consumer preference, increase in incidences of pollution, rapid urbanization, growth in awareness, breakthrough in new technologies and high disposable income positively affect the kraft paper market. Furthermore, rise in e-commerce and retail sectors, and product premiumization extend profitable opportunities to the market players in the forecast period of 2021 to 2028.
The kraft paper market is expected to witness market growth at a rate of approximately 3.25% in the forecast period of 2021 to 2028.
COST ESTIMATION
Plant Capacity 40 MT/Day
Land & Building (14,130 sq.mt.) Rs. 14.89 Cr
Plant & Machinery Rs. 42.35 Cr
Working Capital for 1 Month Rs. 4.61 Cr
Total Capital Investment Rs. 63.22 Cr
Rate of Return 31%
Break Even Point 60%
CONTENTS
INTRODUCTION
MARKET OVERVIEW
GLOBAL
KEY MARKET PLAYERS OPERATING IN THE KRAFT PAPER MARKET ARE
ETHIOPIA
USES/APPLICATIONS
OVERALL, THE USES OF PAPER ARE MANIFOLD
SPECIFICATIONS
TABLE 1 REQUIREMENTS OF KRAFT PAPER
TABLE 2 OPTIONAL REQUIREMENTS OF KRAFT PAPER
EACH PACKAGE AND ROLL SHALL BE MARKED WITH THE FOLLOWING INFORMATION:
PACKAGE
ROLL
MANUFACTURING PROCESS STEPS
PULPING
SCREENING OF PULP
PULP BEATING
REFINING
PAPER MAKING AND FINISHING
FORMING OF WET WEB
PRESSING WET SHEET
DRYING SHEET:
PROCESS FLOW
ENGINEERING DESIGN CONSIDERATIONS
PLANT & MACHINERY SPECIFICATIONS (TYPICAL) FOR KRAFT PAPER FROM AGRICULTURE RESIDUE
POLLUTION CONTROL IN PULP/PAPER INDUSTRIES
PROCESSES AND CHARACTERISTICS OF LIQUID EFFLUENTS
CHEMICAL CHARACTERISTIC OF EFFLUENT FROM (KRAFT) PULP AND PAPER MILL
POLLUTION CONTROL - LIQUID EFFLUENTS
IN-PLANT MEASURES
PROCESS CHANGES
COMPLETE MACHINERY MANUFACTURERS/PLANT SUPPLIERS
SUPPLIERS OF RAW MATERIALS
UTILITIES PER MONTH (ESTIMATED)
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
RAW-MATERIAL SUPPLY:
MARKETS:
POWER AND FUEL SUPPLY:
WATER SUPPLY:
CLIMATE:
TRANSPORTATION:
WASTE DISPOSAL:
LABOR:
REGULATORY LAWS:
TAXES:
SITE CHARACTERISTICS:
COMMUNITY FACTORS:
FLOOD AND FIRE CONTROL:
GENERATION & MANAGEMENT OF WASTES/GREEN BELT
WASTE WATER (ESTIMATED)
WASTE (ESTIMATED)
THE ABOVE DATA IS TO BE VALIDATED DURING EIA/EMP STUDY
ETP FACILITY IS TO BE INSTALLED BASED ON THE STUDY
SEWAGE AND WASTE TREATMENT FACILITY
HEALTH SAFETY AND ENVIRONMENT
ANTICIPATED ENVIRONMENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
HSE REQUIREMENT
PROPOSED IMPLEMENTATION SCHEDULE
PROJECT FINANCIALS
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
PRELIMINARY PLANT LAYOUT
CONCLUSIONS
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS
