Detailed Project Report on paper mill [kraft paper, duplex board, art paper, maplitho paper]

PAPER MILL [KRAFT PAPER, DUPLEX BOARD, 

ART PAPER, MAPLITHO PAPER]

[CODE NO.4119] 

The recovery of waste paper is traditional in the paper and paper board manufacturing industry. The importance of utilisation of waste paper in the paper and board industry should not be under estimated. It furnishes about 30 percent of all the fiberous raw materials consumed in the paper and board mills in the U.S.A. Europe and Japan.

The establishment of the local manufacture of paper board in a country after proceeds that of paper pulp. In this case, waste paper is one of the first sources of fiberous material to which resources is taken to reduce the purchase of the pulp. Waste paper in fact, a source of prepared fibre which needs only to be placed in suspention in water in order to obtain a pulp, making possible the formation of sheets of paper or paper board a very simple treatment which is within the ability of artisans.

The utilisation of waste paper supplements of a great extent the overall fibre requirements in any conuntry, every possible attempt should be made to recover waste paper for its being reconverted into paper, specially in those regions where it is difficult to get sufficient and cheap raw materials for manufacture of paper and paper boards.

It may be reasonably anticipated that the rate of recovery of waste paper will gradually increases to a maximum of 35 percent speciallq in those countries which have a lower figure recovery today. Measures to increases recovery of waste paper such as propoganda on the value of waste paper etc. Though the establishment of waste paper association are very essential and timely section should be initiated to save the fibrous material from decay or destruction.

Paper manufacturing industry in India has limited fibrous raw material resources and will not be able to give up its reliance on waste paper supply as cheap raw material. It wills rather increasing its dependence on waste paper increasing. There is no doubt that special appeals will also increase salvage of waste paper.

Paper form a commodity of prime importance to day from the parts of view of mass communication, education and industrial and economic growth. The art of paper making was first discovered in China in and around 2nd century. B.C. pan where it travelled slowly west ward and reached the prantiens of Europe. By the end of 14th century, a member of paper mill existed in Europe, particularly in Spain, Italy, France and Germany. the invention of printing in 1956 brought a vastly in creased demand for paper and paper-manufacturing was introduced to England. America followed in 1690.

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 manufacture landable efforts are being make in this direction.

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 and low in ligrin content. Most ideal raw material for paper products is bamboo. Other sources are bagasse and hardwoods like jute stick must be developed and good quality paper pulp make by blending with bamboo fibre.

Over recent years, the emergencies of mini paper plants on a reality seems to hold the promise of adding new horizons to the development and growth of Indian paper industry. In may be noted with concern that the large sector of this industry for quite sometime, has failed to sustain any appreciable growth due to various factors eg. The plant being highly capital intensive low rats of return and the raw material bottlenecks etc. mini paper plants are viewed as an effective remedy to the current ailments of the paper industry as they involve much less capital cost and are proved to be technically feasible and economically viable these plants can be erected on the basis of fully indigenous expertise, knowhow and machinery. Moreover, they after an effective means of lasing considerably the burden an conventional raw materials.

The paper industry of India is faced with numerous difficulties, some of which are given below:

1. Shortage of Fibrous Raw Material

     The lack forest resources requires long range planning for development of improved bamboo has vesting utilization of bagasse, jute etc.

2. High process and Shortage of Chemicals

Shortage of sulphur, salt cake (Na2So4) and chlorine with corresponding high prices place in the Indian paper industry to a great disadvantage in attempting to export paper product to a regement of foreign exchange position. This forces a great deal more attention and chemical recovery methods.

Due to the above problems, it become necessary to use simple and more scientific methods for the manufacture of paper products. Due to the lack of the fibres material jute stick is now being started to be wed as the starting material. the  paper produced  from  jute  is very hard  and  has  comparatively  high tensile  strength. Move over, the chemicals used are available indigenously without any difficulty. There are move than 30 to 40 paper industries producing in public and small scale sector. The other factors which can be kept in view in selecting the raw materials.

1. The fibres of the raw material should be of high strength. 

2. Strength methods used for preparing the pulp shaved be easy and hot be complicated. 

3. Properties of the product shaved are of quality by seeing the above problems and jute sticks are quite suitable for the production of paper. A good supply of jute sticks should be ensured by the suppliers.

Mini paper plants are mainly dependent on supplies of waste paper and rafs. They also make pulp out of cereal straw and other agricultural residues. A further important factor in favour of the mini paper plants is that their consumption of chemicals is far less than in the large scale units, and the power requirements are also less. The quality of paper produced in mini paper plants is, however, some what inferior to that obtainable in large scale units.

It may be noted here, that while the large units form the care of the industry, the mini plants can play a very effective role by augumenting the indigenous  production of several varieties of paper where quality is not of prime importance, and effectively utilizing the vast resources of unconventional raw materials, which have hither to been rather untapped.

COST ESTIMATION

Plant Capacity                                   150 Ton/Day  

Land & Building (48,000 sq.mt.)  Rs. 33.32 Cr    

Plant & Machinery                            Rs. 49 Cr 

Working Capital for 2 Months            Rs. 26.21 Cr 

Total Capital Investment                  Rs. 114.25 Cr 

Rate of Return                                  40%

Break Even Point                               44%

• INTRODUCTION
  
• 1. SHORTAGE OF FIBROUS RAW MATERIAL
• 2. HIGH PROCESS AND SHORTAGE OF CHEMICALS
• USES AND APPLICATION
• BESIDES, THE END USE OF PAPER AND PAPER PRODUCTS ARE,
• STANDARD QUALITIES OF WASTE PAPER
• GROUP A - ORDINARY QUALITIES.
• MIXED PAPER AND BOARD NO. 2:
• MIXED PAPER AND BOARD NO. 3:
• BOARD CUTTINGS:
• MILL WRAPPERS:
• CORRUGATED CONTAINERS:
• MIXED PAMPHLETS AND MAGAZINES:
• OVER ISSUED PAMPHLETS, BROCHURES AND MAGAZINES IN BUNDLES
• COLOURED LETTER (OR COLOURED RECORDS)
• LIGHT COLOURED LETTERS (OR LIGHT COLOURED RECORDS)
• WHITE PAMPHLETS, WITHOUT CARD BOARD
• WHITE PAMPHLETS WITHOUT CARD BOARDS, WOOD FREE:
• GROUP B - MIDDLE QUALITIES:
• GROUPE C - HIGH QUALITIES:
• B. I. S. SPECIFICATION
• B.I.S. SPECIFICATION FOR KRAFT PAPER
• SCOPE
• GRADES
• REQUIREMENTS
• MATERIAL
• FINISH
• SIZE AND TOLERANCE ON SIZE
• PHYSICAL REQUIREMENTS:-
• TABLE 1 REQUIREMENTS OF KRAFT PAPER
• TABLE 2 OPTIONAL REQUIREMENTS OF KRAFT PAPER
• PACKING AND MARKING
• PACKAGE
• ROLL
• USES & PROPERTIES OF DUPLEX BOARD
• GC DUPLEX BOARD
• GC1 BOARD
• GC2 BOARD
• GD DUPLEX BOARD
• GT DUPLEX BOARD
• BOOKBINDING BOARD
• APPLICATION OF DUPLEX BOARD
• GSM RANGE
• MARKET OVERVIEW OF PAPER INDUSTRY
• CONSUMPTION BY COUNTRY
• PAPER & PAPERBOARD PRODUCTION & CONSUMPTION FOR NEPAL
• MARKET POSITION OF KRAFT PAPER
• GLOBAL KRAFT PAPERS MARKET CLASSIFIED ON THE BASIS 
•     OF REGION AS FOLLOWS:
• COATED PAPER AND THEIR VARIETY
• VARIETIES
• MACHINE-FINISHED COATED PAPER
• COATED FINE PAPER
• STANDARD COATED FINE PAPERS
• LOW COAT WEIGHT PAPERS
• ART PAPERS
• OTHERS
• USES AND APPLICATION OF MAPLITHO PAPER
• SPECIFICATION OF MAPLITHO PAPER
• BASIS OF PAPER MANUFACTURING
• A CONICAL REFINER MACHINE TO IMPROVE PULP QUALITY
• THE MAIN STEPS OF TYPICAL PAPER MANUFACTURING
• TECNICALITIES IN PAPER MANUFACTURING
• CHEMICAL PULPING
• MECHANICAL PULPING
• DE-INKED PULP
• THERE ARE THREE MAIN CLASSIFICATIONS OF RECYCLED FIBRE:
• ADDITIVES
• PRODUCING PAPER
• FINISHING
• PAPER GRAIN
• MANUFACTURING PROCESS OF KRAFT PAPER
• PULPING:-
• SCREENING OF THE PULP:-
• PULP BEATING & REFINING:-
• REFINING:-
• PAPER MAKING AND FINISHING:-
• FORMING OF WET WEB:-
• PRESSING THE WET SHEET:-
• DRYING THE SHEET:-
• PROCESS FLOW DIAGRAM FOR MANUFACTURE OF KRAFT PAPER 
•    FROM WASTE PAPER
• FLOW SHEET OF MANUFACTURE OF PAPER
• FORMING OF WET WEB, PRESSING THE WET SHEET AND DRYING 
•     THE SHEET
• METHOD OF PREPARATION OF DIFFERENT TYPES OF PULPS
• SEQUENCES IN PAPER MANUFACTURING
• STOCK PREPARATION
• PAPERMAKING PROCESS
• COATING PROCESS
• FINISH PROCESS
• PROCESS OF MANUFACTURE [WRITING AND PRINTING PAPER]
• THE DIFFERENT SYSTEMS MAY BE DESIGNED AS FOLLOWS:-
• STOCK PULPED AT LOW DENSITY AND FIBERIZED BY RAPID 
•    PUMP CIRCULATION:-
• SCREENING AND RIFFLING:-
• WASHING:-
• BLEACHING:-
• BEATING:-
• SHEET LIFTING:-
• PAPER COUCHING:-
• PAPER DRYING:-
• PAPER PRESSING:-
• PAPER CLEANING:
• PAPER GLAZING:-
• SURFACE SIZING:-
• DEINKING OF WASTE PAPER:-
• SECONDARY FIBER PULPING:-
• HIGH-DENSITY-TYPE SECONDARY PULPING SYSTEMS THAT IS AVAILABLE
• THERE ARE TWO BASIC STEPS IN THE DEINKING.
• ALL DEINKING SYSTEMS HAVE THE FOLLOWING STEPS:-
• VERTICAL CIRCULATION DEINKING WITH BREABEN BEATER
• TESTING PAPER
• A. MOISTURE
• 1. MOISTURE CONTENT
• 2. SUBSTANCE BASIS WEIGHT OF PAPER.
• 3. THICKNESS OF CALIPER:-
• BULK
• THICKNESS IN MICRONS
• 4. TENSILE TEST:-
• 5. BURSTING STRENGTH:-
• THE SHOPPER SALEN TESTER
• EXPRESSION OF RESULTS
• 6. POROSITY:-
• SIZING AND ABSORBENC TESTS
• 7. PROCEDURE:-
• 8. OPTICAL PROPERTIES:-
• GLOSS
• OPACITY
• BRIGHTNESS
• COLOUR
• OPTICAL BLEACHING AGENTS
• SMOOTHNESS
• MANUFACTURING PROCESS OF COATED DUPLEX BOARD
• RAW MATERIAL SELECTION
• FLOW DIAGRAM TOP LINER
• FLOW DIAGRAM PROTECTIVE LINER
• FLOW DIAGRAM BOTTOM LINER
• FLOW DIAGRAM FILLER LAYER
• POLLUTION CONTROL IN PULP AND PAPER INDUSTRIES (IN DETAIL)
• PROCESSES AND CHARACTERISTICS OF LIQUID EFFLUENTS:-
• COMMON PULPING PROCESSES
• CHEMICAL CHARACTERISTIC OF EFFLUENT FROM
• A LARGE SULPHATE (KRAFT) PULP AND PAPER MILL USING CHEMICAL
•     RECOVERY
• POLLUTION CONTROL FOR LIQUID EFFLUENTS
• INPLANT MEASURES
• PROCESS CHANGES:-
• COMPLETE MACHINERY MANUFACTURERS /SUPPLIERS FOR PAPER PLANT
• SUPPLIERS OF RAW MATERIALS
• WASTE PAPER
• CAUSTIC SODA
• ALUM
• ROSIN
• LIME POWDER

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)