PAPER MIDDLEAST pulp, paper, tissue
The Magazine dedicated to the Pulp, Paper and Tissue Industry in the Middle East
N°21 - Autumn 2013 Head Ofﬁce / Publisher ENP SA firstname.lastname@example.org 36, rue Stanislas Julien - 45000 Orléans France Tél. +33 238 42 29 00 Publisher STÉPHANE RICHARD email@example.com Editor in chief Lebanon RIMA DIB firstname.lastname@example.org Correspondants Syria AHMED AL SLEEBA email@example.com Jordan RAMI HOURANI firstname.lastname@example.org Advertising Middle East email@example.com Tel: +961 32 24 953 International Advertising STÉPHANE RICHARD firstname.lastname@example.org FRANÇOIS HÉNIN email@example.com Tel: +33 238 42 29 00 Fax: +33 238 42 29 10 Graphic Designers ELHAM EL MASRY GHALI SIMON & PARTNERS Subscription MATHILDE SEVESTRE firstname.lastname@example.org
he Middle East region may still remain in the top news for a couple of years.
No doubt many countries in the Arab World, even if not directly involved in the political instability, are risking theirs; therefore, doubling their efforts to maintain the security level on one hand, and trying to provide opportunities of growth to their economies by making internal reforms and encouraging investments on the other. Dubai for instance, is referred to be among the top destination for investors, the high level of its leaders’ awareness is enabling it to maintain security & stability, consequently to diversify its economy and develop growth. Qatar as well as Saudi Arabia possibly on a lesser degree, each is maintaining a certain level of stability, while searching for ways to expand their economies to a more globalized market. However, countries such Syria and also Egypt which its economy is one of the most diversiﬁed in the Middle East, and the second largest in the Arab world after Saudi Arabia, is witnessing a higher degree of challenges. Few years earlier to the Arab Spring movement, Egypt was put on the same economical level as Turkey enjoying with a steady level of growth, a modernized economy and new economic trends with open opportunities and investments… Today, the situation has changed, downsized by the different levels from the living to the economical and ﬁnancial standards, Egypt is struggling to support the growing population (over 84 million) on one hand, to stabilize the political obstacles that is paralyzing the country on the other. Does the latest decision of the Central Bank to make cuts on the interest rates, will help boost the economy that is risking from collapsing?
ISSN : 2264-606X Diffusion : 3.000 ex. Algeria, Bahrain, Egypt, Iran, Irak, Jordan, Kuwait, Lebanon, Morocco, Oman, Qatar, Saudi Arabia, Syria, Tunisia, United Arab Emirates, Yemen www.groupenp.com Ofﬁcial Media Partner
Does the international conference lately held in New York to discuss ways to face the challenges that the Egyptian economic reform is witnessing, will give enhancement and solutions the Egyptian government and management will be asked to apply? What is sure is that the months to come will have to reveal it!
Rima Dib email@example.com
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Paper Middleast 21 Autumn-Winter 2013
Toprak will build new recycled cardboard mill in Turkmenistan
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The European Bank for Reconstruction and Development (EBRD) is extending a $5 million loan to Toprak, a leading manufacturer of cardboard packaging in Turkmenistan. The loan proceeds will ﬁnance construction of a greenﬁeld paper-making facility that will produce cardboard from recycled paper. The new mill will be the ﬁrst private paper recycling facility inTurkmenistan. The new facility will be capable of producing up to 25 tonnes of paper per day. Toprak plans to sell a third of this output and use the remaining two-thirds for its cardboard packaging production. Producing its own cardboard from recycled waste paper will signiﬁcantly reduce Toprak’s reliance on imported cardboard. The venture will also have an environmental impact, reducing pollution and recycling waste paper which would otherwise be burnt. The company plans to promote paper recycling in major Turkmen cities.
Double A Alizay mill exports ‘made in France’ paper to Dubai, UAE. After the successful recommissioning, Double A Alizay is now producing and exporting high quality paper that matches the Double A quality standards to key markets in Europe, the Middle East and North Africa. “The ﬁrst consignment to the Middle East is a proof of a successful restart and we are proud of this achievement”, said Thirawit Leetavorn, Double A Senior Executive Vice President, who also shared that this achievement is the fruit of a very good team work and positive spirit of French and Thai teams at all levels. Six containers of high quality paper were shipped out of the Port of La Havre end of July and are expected to reach the Port of Jebal Ali in Dubai by third week of August. More shipments out of Alizay to other Double A key markets will soon follow.
“The EBRD’s main priority in Turkmenistan is to support the private sector, and we continue to provide assistance and ﬁnancing to local manufacturers. This loan will enable our existing client Toprak to integrate its production cycle by using modern recycling technologies and know-how,” said Frederic Lucenet, The EBRD’s Director for Manufacturing and Services.
“This is just the beginning of our commitment to growing the brand in Europe by making France our production base. France is a strategic location and Double A’s acquisition of Alizay is a strategic move to strengthen our global reach and to get closer to our customers”, added Mr. Leetavorn.
In addition to the loan, the EBRD also provided the company with technical cooperation for legal and technical due diligence. The Bank also funded consultancy services from international experts, as there are currently no local experts in the cardboard and paper industry. Toprak is the largest producer of cardboard boxes and other containers in the country. It supplies a range of cardboard packaging products to around 130 clients in diverse sectors of the Turkmen economy, from textiles to food, chemical and other industries.
Employees of Al Seer, Double A’s biggest distributor in UAE stand in front of the ﬁrst shipment out of Alizay mill. The ﬁrst containers of “Made in France” high quality paper were shipped out of the Port of La Havre end of July and have successfully reached the Port of Jebal Ali in Dubai on third week of August. Another shipment under the Double A brand arrived in UAE on 2 September.
Double A Alizay mill has begun producing premium quality paper brands four months after the signing of the deal with the Conseil General de l’Eure. All of this high performance coated and uncoated papers are produced using short ﬁber from KHAN-NA, Double A’s sustainable pulp from Thailand.
cast Yankee cylinder and a MasterReel reeler. Packages Limited is a producer of paper, board and tissue in Pakistan. The company started in 1958 as a joint venture with Swedish packaging producer Akerlund & Rausing. Recently, Packages Limited founded a joint venture in Kasur, Pakistan with Stora Enso. The company employs about 3,000 people and in 2012 posted sales of approx. 185 million euros.
Voith optimizes TM 9 at Packages Limited in Pakistan Pakistani company Packages Limited, based in Lahore, relies on support by Voith to achieve its goal of an environmentally friendly and energy efﬁcient tissue production. In order to further lower energy consumption in production, the TM 9 tissue machine has been continuously improved. At the beginning of 2013 Voith installed head insulation on the Yankee cylinder and additionally improved its internal condensate removal system. That now saves 210 kg of steam per hour. As a positive secondary effect, this increased the speed of the TM 9 to 2,000 m/min. Hyder Ali, CEO of Packages Limited, emphasizes the strong project cooperation: “Voith has been a good partner for us for years. We were very satisﬁed with the installation of our TM 9 tissue machine. From the beginning the machine produced the highest quality, which has not only strengthened our position in the Pakistani market, but has also driven demand from abroad. We are working on an ongoing basis with Voith on further improvement of the machine and to achieve low energy consumption. We have thus succeeded in operating the TM 9 at this new speed level. We are not resting on this success, but rather are constantly working to achieve even higher goals.” The tissue machine delivered by Voith was started-up in the summer of 2008. It has a MasterJet T headbox, a suction press roll concept, a 16-ft 8 papermiddleast
Bellmer Vaahto rebuilds for Union Paper Mills After taking over the paper machine business of the Vaahto Group at the end of January 2013, Bellmer Vaahto was awarded a big order by Union Paper Mills from United Arab Emirates. In order to be able to cope with the booming demand in the ﬁeld of packaging papers in their domestic market, Union Paper Mills opted for the new greenﬁeld installation of a second paper mill in Abu Dhabi’s industrial area of ICAD-3. Al Dhafra Paper Manufacturing Company LLC, U.A.E. will produce testliner and ﬂuting materials in a grammage range of 90-180 g/m. When looking for a used paper machine, the customer discovered such a machine in Finland, that machine, originally built for the production of sack paper, will now be modiﬁed and rebuilt for the manufacture of testliner and ﬂuting materials, Bellmer Management conﬁrmed. Union Paper Mills have decided on Bellmer Vaahto Paper Machinery, having a good experience with the Vaahto team during the company’s rebuild project of PM2 in Dubai.
Today, the very same team will operate under the name of Bellmer Vaahto in the Abu Dhabi’s project. Furthermore, the know-how in the ﬁelds of board machine building and headboxes was an important and decisive factor for the UPM management. Bellmer Vaahto Paper Machinery’s scope of supply comprises the short circulation cycle and the headbox, the upgrade of the wire section and the supply of two new dryer groups to increase the drying capacity on the machine. The new size press will be provided by Bellmer. Also, the three under-the-machine pulpers form an essential part of the order. The package comprises also the modernization of the hood technology, a new heat recovery system as well as the size preparation unit. It is worth mentioning that the synergies between Bellmer and the Finnish subsidiary are demonstrated in the diversiﬁed range of supply. Also to note that the retroﬁtting of the existing parts and the manufacturing of the new parts will not only be performed in Finland but also at the Bellmer headquarters in Niefern, Germany.
Production at SCA’s own plant is planned to commence in 2015. “This investment creates a solid platform for us to leverage the favorable growth opportunities that exist in the hygiene products area in India. The investment is in line with our strategy of strengthening SCA’s presence in emerging markets,” says Jan Johansson, President and CEO of SCA and continues: “India’s large population and the low penetration of hygiene products provide the potential for future growth. The aim is to introduce SCA’s hygiene products in the Indian market already in the latter part of 2013.” The brands that SCA intends to launch in the Indian market include the world-leading brands TENA, for incontinence products, and Tork, for Away-From-Home (AFH) tissue. The Libero brand for baby diapers and baby care products and Tempo for consumer tissue will also be introduced.
SAUDI ARABIA The new paper mill is scheduled for startup during 2nd half in 2014. Union Paper Mills that was established in 1987 is today a leading manufacturer of packaging papers made from recycled papers in the United Arab Emirates. Bellmer that was established in 1880, has been since, the personal and high performance machine and plant manufacturer to serve the paper industry around the globe.
SCA invests in India SCA will invest about SEK 150m in local production of hygiene products in southwest India.
Multipak to enhance paper & aluminum packaging With the new ﬂexographic printing machine, the Lebanese owned paper packaging manufacturer Multipak aims at enhancing the paper & aluminum packaging, and the printing quality at its Jeddah based mill’s location. The Multipak ﬂexographic printing machine runs at a maximum speed of 250m/min, and is capable in printing up to 8 colors on ﬂexible packaging products with higher resolution and good registration. The Multipak’s machine is able to supply an enhanced printing service, and able to provide an attractive paper and aluminum packaging design and an effective client brand, delivering an efﬁcient product to meet with the customer’s demands and expectations. papermiddleast 9
Established in 1997, Multipak manufactures specialty paper bags (handle bags, self-opening sack SOS bags and satchel bags), paper rolls, paper sheets, gift wrap, and paper core. Multipak’s paper products range from commercial to high-quality grades. All products may be coated with select materials and may be printed in up to 8 colors. The paper converter serves Saudi Arabia, Gulf Corporation Council (GCC), Middle East and North Africa markets. Multipak is a Napco company and member of INDEVCO Flexible Packaging, a division of INDEVCO Group.
Nuqul Group to achieve a selfdeclared “A+” disclosure level The ﬁrst among the industrial conglomerates; the Nuqul Group, chieved a self-declared “A+” disclosure level in its 5th Sustainability Report submitted to the UN Global Compact Initiative. The 5th annual sustainability report published by Nuqul Group covers the year 2012 and falls under the Group commitment towards sustainability and the Group active role as a member of the UN Global Impact Initiative. The report is developed in accordance with the Global Reporting Initiative (GRI Guidelines), and achieved a self-declared “A+” disclosure level, which is considered the highest level of transparency within the GRI framework.
of its kind in Jordan, with only one such council established in the MENA region, and in KSA. Nuqul Group’s stakeholder Council comprises representatives from key stakeholders including owners, employees, customers, suppliers, academia, PR and NGO’s. It actively engaged in reviewing the report and issued and independent assurance statement for the Group’s 2012 sustainability report in accordance with the GRI’s report content and quality parameters. The CEO of Nuqul Group, Salim Karadsheh stated: “This report marks our ﬁfth year for disclosing our sustainability performance, and celebrates our renewed commitment to the UN Global Compact with its ten principles. Our sustainability strategy aims to address all key sustainability challenges that face our business from natural resource availability to sustainable human resources management practices, and we always strive to maximize the sustainability value for our business and all our stakeholders.” “Nuqul Group adopted the principles of sustainable development in 2007 when the Group became signatory to the UN Global Compact and its ten principles. Since then, Nuqul Group has made every effort to integrate sustainability into its business approach. In 2012 we were able to reduce the environment impact for some of our products, and in 2013 we look to continue our commitment towards sustainable development in all aspects of our operations.” Dr.Tareq Abu Ghazaleh, Director of Operations Support commented. The Highlights of Nuqul Group’s 2012’s Sustainability report:
Nuqul Group established a stakeholder council to review and provide advice on the content and quality of the report and provide recommendations on future sustainability direction of the Group.
In 2012 Nuqul Group achieved several accomplishments to name a few: It secured the continued growth in the market with increased revenues for Fine Hygienic Holding.
The stakeholder Council is considered as a global best practice in stakeholder engagement and sustainability management and it is a ﬁrst
It was the 1st in the region to conduct product life cycle assessment according to the ISO 14040 guidelines.
Nuqul Tissue in Egypt was the ﬁrst in the Industry in the region to secure ISO 50001 certiﬁcation for Energy Management, and it registered its co-generation project under the Clean Development Mechanism – Kyoto Protocol.
companies and supporting industries; while the Promise Holding includes diverse investments in different sectors and modes.
Fine Classic 300 facial tissue received product of the year award in Lebanon.
Nuqul Group’s Corporate Social Responsibility program continued its growth with the signing of a pioneering “Public Private Partnership” agreement with the Ministry of Municipal Affairs and the Municipality of Dair Abi Saeed which aimed at expanding projects in the area to include a packaging and labeling unit, a farming project, a processing unit among other activities that focus on deep development approach. The ﬁne converting facilities in Jordan, Egypt, KSA and Dubai achieved a zero manufacturing waste to landﬁll. The Nuqul Tissue facilities achieved best practice in pulp yield ratio and a 3.4% reduction in water consumption. For each 1 million boxes produced at Nuqul Group’s Perfect Printing Press, a12% reduction in electricity consumption was achieved. A47% increase in the number of front line employees receiving training took place as well as a 42% decrease in Accident Frequency Ratio at Fine Hygienic Holding, and a 77% decrease in Lead Time to Resolve Customer Complaints for Fine Facilities in Egypt, Jordan, and KSA. Moreover, the Elia Nuqul Foundation granted 26 scholarships during that year.
Parteks to receive a tissue production line from Toscotec Toscotec the Italian leading paper machinery manufacturer is to supply a tissue production line to the Turkish Parteks Paper Industry Ltd. The tissue line will be installed at the plant location in Kayseri in Turkey. The start-up on the machine is scheduled for the ﬁrst quarter of 2014. The new production line will produce 75 tons/ day of high-quality facial, toilet and towel grades, with a machine width of 2.85m, and a design speed of 1600 m/min. The delivery will include a MODULO Plus tissue machine with a single layer headbox, a single press conﬁguration, the Toscotec TT SYD 12 FT steel yankee dryer, as well as an approach ﬂow with the renewed Toscotec technology TT SAF®. The delivery will also include the electrical and control systems, the steam and condensate, and the natural gas heated hood unit that Milltech (Toscotec’s provider) will ensure.
About Nuqul Group:
Toscotec’s supply will also comprise a 2 unwind stands rewinder TT WIN-P to compete the package order.
Celebrating 60 years of achievements, innovation and impacting surrounding communities, Nuqul Group today runs different investments and industries led by an empowered 5100 team members spanning several continents. Nuqul Group embodies two major holding entities; FINE Hygienic Holding (FHH) being the umbrella for paper mills, FINE hygienic paper
According to the company’s philosophy and concept that is based on the energy-saving , the new Toscotec project will focus basically on reducing energy consumption, the usage of selected raw materials for the manufacturing process, the recovery and re-use of the processed water, the low emissions such noise and pollutants, in addition to the focus on the green papermiddleast 11
energy adoption through applying of the steel yankee dryer technology.
this partnership to offer Process Systems Engineering (PSE) solutions in the GCC countries.
Parteks Paper Industry Ltd. is a fully integrated large manufacturer of virgin pulp, recycled paper for household and industrial tissue, corrugated cardboard and ﬂuting paper.
Speaking of the development, Senthil Kumar, Vice-President and Senior Partner of BWIR says, “The PSE practice is one of the fastest growing practices in BWIR and I am conﬁdent about our growth in the GCC. I am delighted to have Prasad join us, whose rich experience and vast network we would leverage. Our partnership with Amran combines credibility, market understanding and depth of our engineering offerings.”
The company was established in 1996 in Kayseri (Central Anatolia) in Turkey on an area of 70,000 m² comprising a tissue machine and a Fluting machine and a corrugating line, with a total daily production of 100 tons on both lines. With more than 300 employees, the company ensures to present customer high quality and environmentally friendly products on competitive price. Toscotec is the leading Italian company in the design, manufacture and delivery of complete plants and equipment for the production of tissue, paper and board. Located in Lucca Italy, the company has been active since 1948 delivering complete plants and machine rebuilds throughout the world with particular focus on turnkey projects and the dedication and the care of its customers. Through this latest project, Toscotec signs its 10th order of the year 2013, and continues its expansion and strengthening its position in the challenging Middle East market.
BWIR Partners with Amran ,Z[HISPZOTLU[ 33* [V VăLY process systems engineering solutions in the GCC Barry-Wehmiller International Resources (BWIR) announced a strategic partnership with Amran Establishment LLC. BWIR will leverage
BWIR has brought on Prasad Kalathil as head of its PSE practice. Prasad, a 29-year veteran in the oil & gas and water business, has experience in senior roles with ﬁrms like BP, Cameron, KCC, Degremont and Shanfari. According to BWIR’s Director of Engineering Services, Sridharan Balaiyan, “the goal of PSE practice aligns with our engineering services mission to reduce engineering costs, timely project execution, extending engineering capacity” Amran Establishment LLC, in business since 1978, is one of the leading business houses in Oman, having core businesses in oil & gas, process industry, power. Amran is headquartered in the Sultanate with a sales ofﬁce in Muscat, and has business associations with some of the world’s leaders in relevant sectors. Mr. Said Amran Al Harthy, Chairman and CEO of Amran Group of companies, said of the budding partnership: “I am certain that the peoplecentric approach of Amran and BWIR will be a game changer in the engineering services industry of the Sultanate, especially at a time when Oman is making huge investments in expanding its energy and allied industries”. About BWIR’s growth path in the Middle East, Prasad says, “I am thrilled about this opportunity to drive the PSE practice. Our synergies with Amran only strengthen a common vision to deliver value to clients and employees”.
4 – 6 March, 2014 Dubai, United Arab Emirates www.paperworldME.com
If your business is stationery, discover new momentum with us. Paperworld Middle East is the MENA region’s most focussed and relevant trade show for the stationery and office supplies industry. Visit the exhibition to keep abreast of product developments, discover opportunities, network, and even assess your competitors’ game plan. Pre-register to visit now at www.paperworldME.com/ad5 *Online registration also lets you access the new Business Matchmaking Program, so you can find and connect with specific exhibitors and schedule meetings well before you visit the show.
An eye on Unipak Nile company through the General Manager Fouad Khalil With a background in Industrial Business to holding different managerial positions in the organizational ladder, Fouad Khalil General Manager of Unipak Nile - Egypt, a unique character and down to earth personality with a strong expertise in Human Resources and a clear and optimistic vision on the employee development. Mr. Khalil believes that factors such as honesty, teamwork, a positive attitude, synergy, hard work, and delegation bring “success”. These values are deep rooted in the philosophy of the INDEVCO Group Founder and Former Chairman Mr. Georges Frem whose words gave the basis principles for the group community. He once said: “what is good for the community is good for our company. What is good for the company, we will strive to do excellently and in a way that enriches the lives of our people...“ In the following pages, we will have the opportunity to get to know more about Mr. Khalil and Unipak Nile Company, shedding the light also on the corrugated industry in Egypt. By Rima Dib
Mr. Khalil ﬁrst, would you please tell us how did you start your career, and when? I completed my bachelor’s degree in Business Administration du“Once management is ring 1986 from the committed and focused, steering the organization University of Saint towards continuing Joseph, Beirut. After success and progress graduation, I started becomes easier.” working part time while I was preparing
my master’s degree. In 1989, I completed my MBA from the same university with specialization in Industrial Business. And when did you join INDEVCO Group, and what positions did you hold? During 1989, I joined Unipak S.A.L. as Plant Superintendent; from that point onward, my journey with INDEVCO group began. In 1994, I was promoted to join Easternpak as Production Head, “… I believe that passion while the company gives commitment and started its operations. growth… In 1999, I was pro- … One should ensure moted to Production to integrate physical, Manager and to Plant mental, social, and Manager in 2003, then spiritual activities.” to Plant and Administration Manager in 2008. I received the opportunity to become Operations Manager at Easternpak in January 2009, and then was promoted to Deputy General Ma-
nager in November. In 2010, I was appointed to General Manger for Easternpak. Now and since September 2013 I hold the position of General Manager at Unipak Nile. Mr. Khalil, what are the major goals you are trying to achieve at Unipak Nile? To achieve our IPC (Indevco Paper Containers) strategic goals and Unipak Nile’s growth plan. We continuously try to ensure high standard services in line with customer expectations. Since we are in a multinational environment, we make the effort to adapt to Egypt’s culture, and focus on creating a positive work environment to solidify our brilliant team work and unity. Since Unipak Nile faces tough competition, our aim is to be efﬁcient through optimizing our resources to differentiate Unipak Nile and ensure market penetration.
ning food safety stan- “To stay on top of the dards through various market, we try to restrict certiﬁcations. To stay economic and political on top of the market, factors by converting we try to restrict eco- them to opportunities nomic and political by quickly and positively adapting to change.” factors by converting them to opportunities by quickly and positively adapting to change. Wishing you all the success! Now Mr, Khalil, and since you have held different positions at the organizational ladder, we would like to know about what are the unique factors, in your opinion, that contribute towards organizational success? I always believe that contributing to organizational excellence is the very basic require-
We aim to supply a wide range of industrial and agricultural packaging solutions, in addition to catering and delivery boxes. We also offer sustainable packaging solutions while adapting the latest technologies. We emphasize on sustaipapermiddleast 15
ment to grow as successful business and obtain conďŹ dence and support. There are unique factors that need to be nurtured and sustained. I believe factors such as honesty, teamwork, a positive attitude, synergy, hard work and delegation bring success. Our INDEVCO values have brought many positive changes and achievements which I have transferred to my team for their understanding and practice. The value factors are vital to anchor organizational performance and sustained teamwork. Once management is committed and focused, steering the organization towards continuing success and progress becomes easier. You are absolutely right Mr. Khalil! Following your long experience with INDEVCO Group and holding different positions in different countries, how did you succeed in adopting different cultures? I strongly believe that the understanding of a culture, its people, and its positive aspects, enables us to establish ourselves in both its business and social life. Each country has its own recognized culture
that should be respected. Therefore, understanding, practicing, and focusing on cultures with a positive mind-set is important. If these are in line with INDEVCO va- â€œCompetition is very lues, it can help contri- strong which forces bute to organizational corrugated industries to excellence and employee be highly innovative and dynamic.â€? development. And now Mr. Khalil, about Unipak Nile, when was it established, and how many employees are presently working with the company? Unipak Nile was established in 1996 and is one of the market leaders in Egypt, and there are presently 470 employees working with the company. And what are the current projects at the company? Since INDEVCO strongly believes in continual improvement, we are always in the process of expansions in line with our business growth and market demand by building new warehouses, upgrades in line with our strategic growth, additional machines in line with market demand, in-house training for our staff and streamlining processes by successfully documenting quality
management systems; to ensure efďŹ cient interaction between processes. And who are the sisters companies to Unipak Nile? UNIPAK Nile is a member of INDEVCO Paper Containers (IPC), a division of INDEVCO Group, operating corrugated packaging manufacturing and converting companies across the Middle East, North Africa and Europe. The sisters companies are: s 5NIPAK SAL IN ,EBANON ESTABLISHED IN s %ASTERNPAK ,TD IN $AMMAM +INGDOM OF Saudi Arabia, established in 1993 s 5NIPAK(ELLAS 3! IN #RETE 'REECE ESTAblished in 2008 s 5NIPAK#YPRUS IN #YPRUS ESTABLISHED IN
â€œA work-life balance enhances productivity and creates inner peace.â€?
Is Unipak Nile friendly to the environment, how? As part of INDEVCOâ€™s philosophy, UNIPAK Nile is committed to environmental sustainability. We aim to increase awareness in our mar-
ket, and to contribute to the green evolution by reducing our footprint â€œThe future of throughout our production corrugated board lifecycle, recycling, and in Egypt and the increasing the manufac- Middle East is very turing of sustainable pro- promising.â€? ducts. Then, which markets do you target? At Unipak Nile we focus on the Egyptian and North African markets, in addition to the European markets within a variety of sectors. Following your experience in the corrugated industry ďŹ eld, how do you describe the actual status of the corrugated industry in Egypt? Competition is very strong which forces corrugated industries to be highly innovative and dynamic. The competition is fragmented and intense due to various levels of players (from large to small corrugated companies). papermiddleast 17
materials that are eco friendly, and renewable, and, the trend is moving from Europe to our region to use more environmental friendly products, safe for food contact, and lightweight. All forecasts are indicating a market growth!
Please tell us about Egypt’s corrugated packaging market The Egyptian packaging market is dynamic and challenging yet offers corrugated board manufacturers many possibilities of development. And how is that? Competition increases challenges and pushes us to be innovative, provide lower costs, and “Be environmentally maintain quality of service. friendly and The development therepromote recycling in fore will be through new order to contribute designs, use of recycled toward saving our and virgin paper, and cost planet.” savings in production lines. What is the main handicap to this industry? And what solutions are required? A main handicap is the shortage of skilled labor and supply of local raw materials. The unstable political situation hampers tourism and the“Understanding, refore; all the industries the practicing, and including focusing on cultures corrugated inwith a positive mind- dustry are afset is important.” fected by this turbulence. How about the future of the corrugated board? The future of corrugated board in Egypt and the Middle East is very promising, ﬁrstly; because of the nature of the raw 18 papermiddleast
Mr. Khalil, you have a long experience in this business, therefore; what message do you wish to give to the young people who are getting involved in the corrugated industry business? I wish to voice the following: be environmentally friendly and promote recycling in order to contribute toward saving our planet.
“Employees need a positive mindset culture where they are inspired and motivated.”
And what are your future plans? I aim to engage our teams and direct them towards organizational improvement by building and demonstrating a role model behavior. Employees need a positive mindset culture where they are inspired and motivated. Away from work Mr. Khalil, how do you spend your free time? With sports, mainly walking, swimming, and skiing in winter time. On the other hand, I enjoy reading very much. And how do you wish to conclude this discussion? On a professional level, I believe that passion gives commitment and growth; on a personal level, I think one should ensure to integrate physical, mental, social, and spiritual activities. A work-life balance enhances productivity and creates inner peace.
Process & techniques
Wires & Fabriks India, 50 years of excellence in Paper Machine Clothing
ires & Fabriks (S.A) Ltd. ( W&F ) was established in 1963 and since 1985, the company is listed on the national stock exchange. Headquartered in Jaipur, 250 Km from New Delhi, W&F is the leading manufacturer and supplier of Paper Machine Clothing in India and is ISO 9001 compliant since 1994. Later this year the company would be celebrating their 50 years of excellence and contribution to paper industry. W&F manufactures full range of Forming Fabrics and Woven & Spiral Link Dryer Screens for paper machines, including woven fabrics for the Pulp section and Sludge dewatering machines. Stainless Steel & Bronze wire-cloth are also manufactured for pulp, paper, board and ﬁbre cement applications.
Machine Clothing Industry from last 30 years and has been closely associated with the Middle-East Paper Industry and has seen it growing to its present stature. He shares “ Wires & Fabriks (S.A.) Ltd, has always demonstrated its ability to invest for the future on newer technologies, innovative products and the best in class machinery. We have come a long way and now offer world class quality products and services in a globally competitive environment. Our huge experience and current pool of technical experts help us solve critical problems and deliver value addition to customers for running their machines better.” In 2006, W&F introduced the SSB ( Shute Support Binder) range of forming fabrics branded as STL –Shute Support Triple Layer Fabric.
W&F exports over 30% of their production to 30 countries world wide. It is the only PMC manufacturing company in India having ofﬁcial recognition of its in-House R&D Department, from Ministry of Science & Technology, Government of India, since 1984. Product usage references are available for all varieties of paper machines and for all types of paper grades. Innovative solutions are provided through products and services. We interacted with Mr.DK Raina , Exec. Vice President –Marketing who has been in Paper 20 papermiddleast
In 2010, it entered into a technical collaboration with Albany International Inc. for the most modern SSB Forming Fabrics, enabling them to provide world class value added products and services for the increasingly cost and quality conscious modern paper mills. These fabrics have a potential to deliver higher
life, lower energy and chemical demands, improved retention and formation and assure a cleaner run.
As per Mr. Raina, the company always strives for acquiring the latest designs and technologies available globally. The company has recently launched Uno-Tier Dryer Screen, which is a unique two-tier ﬂat warp weave pattern screen with controlled permeability, recommended for Unirun positions and high speed machines. The higher surface contact area helps to increase the heat transfer with better sheet support thus lowering the energy consumption and has a potential for, higher life. W&F has already received orders for these products from prestigious mills in India and abroad.
Mr Raina informed that investing in modern machinery and latest technologies is inherent in the company’s outlook. In the recent past, the company has undergone a massive expansion and modernization drive which included installation of state-of-the-art weaving looms ﬁnishing tables supplied by global leaders in this technology. Today the company is equipped with sophisticated warping equipment from Jaeger , ultra modern weaving equipments from Jaeger (Rapier) & Jurgens (Projectile), PLC controlled heat settling
equipment and fully automatic seaming machines from WIS. Keeping people as the key differential, continuous training and skill upgradation is given high importance. A large talent pool of textile and paper technologists work together to deliver great value add to customers. Through it’s Chemical Division, WF provides a host of specialty and performance chemicals: defoamers, deinking, retention aids, coating additives, binders, enzymes etc. One of their successful solutions is the Drainage Aid through Nanoparticle program where activated Bentonite acts as a scavenger largely independent of the system charge and improves water clarity leading to better drainage and retention of ﬁnes and ﬁbers. The resultant beneﬁts are better machine run ability, lower steam consumption and lower load on recovery systems.
As a commitment towards corporate social responsibility WF supports DISHA – a resource center for the mentally challenged children in Jaipur. Kingsley Industries Limited ( KIL ) is a sister company of W&F providing engineering services and specialized machinery to pulp and paper industry since 1983. Their product range includes machine speed synchronized - oscillating showers , doctor holders and blades , nozzles , ﬁlters etc. In collaboration with OMC – Italy, they manufacture water and ﬁber recovery equipment. Kingsley products are well established as papermiddleast 21
cost effective and high performance products - both in the domestic and international markets including the Middle-East. Mr. Devesh Khaitan, Director, Kingsley Industries Limited, shared with us insights on how Kingley helps their customers in the areas of lubrication systems and ﬁber & water management for pulp and paper industry- “ We have graduated now by expanding our product range into complete range of cleaning , lubrication and accessories and offer complete solutions to our esteemed clients in India, Middle-East and Far Eastern countries. Our water and ﬁber recovery solutions , in collaboration with OMC -Italy have been proven as the game changers and we continue to provide latest and innovative solutions through our global technology partners.” In Middle-East markets, Wires and Fabriks (S.A.) Ltd. currently pursues business with esteemed companies like Obeikan Paper, Middle East Paper Company (MEPCO) , Arab Paper Company (WARAQ) and Gulf Paper Industries in Kingdom of Saudi Arabia. Union Paper, Gulf Paper etc. in UAE are regular
Mr.D.K.Raina Executive Vice President -Marketing Wires & Fabriks (S.A.) Limited
Mr.Devesh Khaitan Director Kingsley Industries Limited
consumers of their products apart from regular supplies to mills in Egypt, Qatar, Kuwait, Oman, Jordan etc. Mr Raina, who is a frequent traveller to Middle East markets explains that W&F has a dedicated technical service team to identify the customer’s needs with a clear focus on Machine Efﬁciency, Energy and Cost aspects by way of periodic machine audits, surveys and CADSCAN drainage studies. The company works closely with the customer as a partner to develop optimized solutions through a combination of products and service. Wires & Fabriks (S.A.) Ltd. has a vision to be a Company of Choice to work with, be it an associate, supplier, customer or stake holder and has the drive to provide sustained value to customers through cost effective latest technology products and reliable services.
Process & techniques
Stickies, Deposit, Ash control in Packaging mills: 5L^ÅV[H[PVUZVS\[PVUZ Stephan Pottier, R&D Project Manager Alain Lascar, Applications & Marketing Director Frédéric Vaulot, R&D Director Kadant 1. Introduction Trends in packaging grades are s ! REDUCTION OF THE BASIS WEIGHT AND SO A LESS THICK PAPER s !N INCREASE OF PAPER MACHINE SPEED s ! LOWER lBRE QUALITY AND AN INCREASE OF CONTAMINATION AND MAINLY STICKIES AND HOT MELT AND ALSO WAXES FOR !MERICAN /## SO CALLED !/## s ! CONCERN ON MINERAL OIL CONTENT IN RAW MATERIALS s -ORE CLOSED WATER CIRCUIT AND MORE SURFACE ACTIVE TENSION COMPONENT RELEASED BY RAW MATERIALS WHICH ALL IN ALL IS INCREASING SURFACE ACTIVE TENSION MATERIAL IN PROCESS WATERS OF THE /## MILLS 4ODAY /## PROCESSES ARE USING PULPING SCREENING CLEANING THICKENING AND SOMETIMES DISPERSING FEATURES 4HESE PROCESSES ARE SURELY EFlCIENT FOR THE MAJORITY OF MACRO CONTAMINANTS SUCH AS MACROSTICKIES WAXES HOT MELTS BUT NOT EFlCIENT ENOUGH OR NOT ACTING AT ALL ON MICRO STICKIES AND SOME MINI STICKIES COLLOIDAL COMPONENTS SURFACE ACTIVE TENSION SUBSTANCES CALLED 3!3 IN THIS ARTICLE AND MINERAL OIL COMPONENTS
(OWEVER MANY CHALLENGES ARE FACED WITH THIS TRENDS AND IT IS ALSO SOME YEARS PAPER MAKERS HAVE SPOKEN ABOUT THIS TRENDS AND IT IS FACT TO SAY THAT VERY FEW OF THEM HAVE INSTALLED THIS KIND OF PROCESSES -AIN REASON WAS THAT THE TECHNOLOGY AND PROCESSES AVAILABLE ON THE MARKET WAS NOT ENOUGH SELECTIVE AND WAS GIVING TO MUCH LOSSES FOR POOR EFlCIENCIES !RE THERE TODAY NEW mOATATION SOLUTIONS AVAILABLE TO SOLVE THIS ISSUE AND BETTER COPE WITH MARKET TRENDS
2. New challenges to be solved in Packaging mills 2.1. The weight reduction trends versus stickies and deposit )N ORDER TO ILLUSTRATE THIS NEW CHALLENGE LETS HAVE A LOOK TO THE FOLLOWING lG
Fig 1 Trends in paper industry Bruno Carre Ctp 2011
!LL THESE ABOVE REASONS AND TODAY SITUATION ARE PUSHING MORE AND MORE PAPER MAKER DOING PACKAGING TO LOOK MORE TOWARD mOTATION TECHNOLOGIES PROCESSES
)F WE LOOK THE IMPACT OF THE STICKY SIZE VERSUS THE PAPER THICKNESS WE HAVE THE FOLLOWING EVIDENCE SHOWN IN lG papermiddleast 23
Fig 2 sticky size versus paper thickness and weight Bruno Carre Ctp 2011
,ETS LOOK TO PACKAGING GRADES AND FOR EXAMPLE mUTING DEVELOPMENTS 3OME YEARS AGO mUTING WAS MAINLY AROUND TO GM 4RENDS HAVE BEEN TO REDUCE WEIGHT DOWN TO GM BUT MAINLY DUE TO PAPER MACHINE RUNNABILITY AND PAPER STRENGTH REALITY IS NOW MORE AROUND GM AS A REALISTIC INDUSTRIAL VALUES 3TANDARD PROCESSES TODAY ARE MAINLY AS DESCRIBED IN THE lG
Fig 3 OCC line standard flow sheet used for European OCC
)N lG PROCESSES INVOLVED REMOVING STICKIES AND OTHER MELTING CONTAMINANTS ARE SCREENING AND CLEANERS %VEN IF A LOT OF PROGRESSES HAVE BEEN DONE IN SCREENING TECHNOLOGIES AND SLOTS SIZE AND +ADANT HIGHLY PARTICIPATE IN THIS DEVELOPMENT WITH THE &IBRE7ALL NEW WEDGE WIRE BASKET WE CAN SEE SOME LIMIT IN REMOVING SMALL SIZE CONTAMINANTS AS SHOWN IN &IG
&IG SHOWS CLEARLY THAT VERY SMALL STICKIES SUCH AS MICRO STICKIES WILL GO BACK TO THE WATER AFTER THICKENING OR PAPER MACHINE WET END AND FOR THE BIG MICRO AND SMALL MINI STICKIES WHICH ARE BETWEEN TO Â«M THEY ARE NOT WELL REMOVED IN THE PROCESSES 4HESE SMALL CONTAMINANTS HOT MELT OR STICKIER ARE FOR SURE LESS DETRIMENTAL TO PROCESSES WHEN YOU ARE DOING THICK PAPERS WITH HIGH GRAMMAGE AND LOW MACHINE SPEED BUT START TO BE A REAL ISSUE FOR DEPOSIT AND MACHINE RUNNABILITY WHEN BASIC WEIGHT AND PAPER THICKNESS ARE GOING DOWN WHICH IS OUR TODAY CLEAR TREND 7HEN THINKING ABOUT IT IT IS CLEAR FOR THE SCIENTISTS THAT NEW AGE IS COMING AND THAT USAGE OTHER TYPE OF SEPARATION TECHNOLOGIES ARE NEEDED )DEA WAS TO LOOK MORE CAREFULLY TO WATER LOOPS AND mOTATION TECHNOLOGIES !NOTHER TO DEMONSTRATE THIS FACT IS TO LOOK AT MORE IN DETAILS $#- EXTRACT MEASUREMENT ON lNES WHICH IS AN EXCELLENT INDICATOR OF MICROSTICKIES AS #TP DEMONSTRATED IT
Fig 5 DCM extract measurement in Deinking mills and in OCC mills Source Ctp 2009
Fig 4 Sticky removal per size Alain Lascar/Alain Fernandez de Grado 2008 Leipzig 24 papermiddleast
&IG SHOWS BIG DIFFERENCE BETWEEN /## AND $EINKING PROCESSES IN $#- EXTRACT IN lNE FRACTION WHICH IS MAINLY MICRO STICKIES PART /F COURSE RAW MATERIALS ARE NOT THE SAME AND LEVEL OF CONTAMINATION PERHAPS DIFFERENT (OWEVER WHEN LOOKING TO MEASUREMENT OF MACRO AND MICRO STICKIES IN THE PULPING STEP DATA ARE NOT
SO DIFFERENT !S A MATTER OF FACT THE DIFFERENCE IN THE lNAL RESULTS IN THE PULP GOING TO THE PAPER MACHINE IS MAINLY DUE TO TECHNOLOGY APPLIED IN EACH PROCESSES )N EACH PROCESSES SCREENING CLEANING STEPS ARE APPLIED (OWEVER IN $EINKING PROCESSES WATER LOOPS BETWEEN PAPER MACHINE AND STOCK PREPARATION ARE MORE SEPARATED AND mOATATION STEPS ARE OPERATING #OULD IT GIVE IDEA OF DEVELOPMENTS FOR THE PACKAGING PROCESSES 2.2. Mineral oils issue in packaging processes. (IGH CONTENT OF MINERAL OILS HAVE BEEN FOUND IN FOOD PACKED WITH PAPER AND BOARDS AND MAINLY THE ONE PRODUCED WITH RECYCLE lBRES 7HEN CHECKING ORIGIN OF THIS FACT CHEMICAL SUBSTANCES FROM THE MINERAL OIL FAMILY HAVE BEEN IDENTIlED -/3( -INERAL /IL 3ATURATED (YDROCARBONS PARAFlNS NAPHTENES -/!( -INERAL /IL !ROMATIC (YDROCARBONS 4HEY ARE AROMATIC HYDROCARBURES !NALYSIS OF TOXICITY HAS BEEN PUT ON THE ONE HAVING LESS THAN CARBONS AS WHEN MORE CARBONS THEIR CAPACITY TO MIGRATE IS VERY LOW &IG SHOWS SOME CONTENT OF MINERAL OIL IN DIFFERENT PAPERS COMING MAINLY FROM THE INK USED
RISK EVEN IF SOME OF THEM HAS BEEN PROVED TO HAVE A HIGH RISK FOR THAT 2.3. Surface active substances More SAS in our processes. 3INCE SEVERAL YEARS THE #ENTRE 4ECHNIQUE DU 0APIER #40 'RENOBLE INVESTIGATES THE BEHAVIOUR OF 3!3 IN RECYCLING AND $EINKING PROCESSES &ROM THIS KNOWLEDGE IT HAS BEEN POSSIBLE TO CORRELATE SEVERAL DETRIMENTAL RUNNABILITY SITUATIONS WITH THE PRESENCE OF UNDESIRED 3!3 7ATER LOOPS EITHER FOR $EINKING LINES OR FOR 0ACKAGING ,INES AND EVEN 6IRGIN lBERS AND #OATED "ROKES "ASICALLY 3URFACTANTS ARE CHARACTERIZED BY A DUAL SHAPE ONE EXTREMITY OF THE MOLECULE IS HYDROPHOBIC THE OTHER ONE IS HYDROPHILIC AS SHOWN IN lG
Fig 7 Typical SAS hydrophobic/Hydrophilic extensions Ctp 2009
Fig 6 Mineral oil content in different paper boards K GROB 2011
)N STANDARD PROCESSES USED TODAY NONE OF THE TECHNOLOGIES INVOLVED ARE ABLE TO REMOVE 3!3 EVEN IF DETRIMENTAL EFFECT OF 3!3 SATURATION HAS BEEN SHOWN AND WILL INCREASE IN THE FUTURE DUE TO MORE RELEASE AS MORE IN RAW MATERIALS MORE CHEMICAL USAGE IN PAPER MILLS AND MORE CLOSE WATER CIRCUITS
%VEN IF IT DOES NOT EXIST AN %UROPEAN LEGAL LIMIT FOR -/3( ET -/!( lRST REPORTS ISSUED CLAIMING RISK OF CANCER BLOW A CERTAIN PANIC SITUATION IN THE INDUSTRY MAINLY FOR PACKAGING IN CONTACT WITH FOOD AND EVEN DRY FOOD
&LOTATION HAS BEEN SHOWN HERE AS A PROCESS ABLE TO DESATURATE THE CIRCUIT #TP APPLIED A PATENT FOR IT AND +ADANT GOT THE EXCLUSIVE USAGE OF THIS PATENT AS WELL AS DEVELOPING mOATATION CELLS FOR THIS OBJECTIVE
&INDING SOLUTION TO REDUCE THEM IN THE RAW MATERIALS AND TO CONTROL THEM IN THE PROCESSES HAS BEEN A NEED FOR PAPER MAKERS
3. Flotation technologies
&LOTATION ALONE IS NOT THE PERFECT SOLUTION BUT IS ACTING ON THEM AND NOT ALL ARE GIVING CANCER
&LOTATION TECHNOLOGIES APPLIED TODAY IN PAPER MAKING PROCESSES ARE s $ISSOLVED AIR mOTATION papermiddleast 25
Fig 8 New Kadant MAK C Cell
s 3ELECTIVE mOTATION BASED ON THE TECHNOLOGY OF $ISPERSED AIR mOTATION $ISSOLVED AIR mOTATION OBJECTIVE IS TO REMOVE ALL SOLIDS IN SUSPENSION FROM THE WATER THANKS TO THE ATTACHMENT OF MICRO AIR BUBBLES TO AGGREGATES OF MATERIAL 4HE AGGREGATES CAN BE INITIATED AND MADE STRONGER WITH ADAPTED COAGULATION AND mOCCULATION CHEMICAL AGENTS /N THE CONTRARY 3ELECTIVE mOTATION OBJECTIVE IS TO SELECTIVELY REMOVE SOME COMPONENTS SUCH AS ASH STICKIES 3!3 OR OTHER HYDROPHOBIC PARTICLES BUT NOT THE lBERS lNES !S THE MAIN DRAWBACK OF mOTATION NOT TO ALREADY BE USED IN THE PACKAGING GRADES IS THE LOSSES IT IS CLEAR THAT OBJECTIVES WAS TO GO TO SELECTIVE mOTATION AND IMPROVE SELECTIVITY WHILE REDUCE LOSSES )T IS EXACTLY THE WAY +ADANT DID RESEARCH AND WHY INTRODUCED THE NEW -!+ # SEE lG 4HE COMBINE EFFECT OF COLUMN mOTATION AND MULTI AERATION CONCEPTS HAVE DRIVEN HIGH SELECTIVITY WHILE REDUCING LOSSES
!S OBJECTIVES WAS TO REDUCE LOSSES AND ACT ON COMPONENT SUCH AS MICRO STICKIES SAS MINERAL OIL THAT ARE CONCENTRATING IN WATER LOOPS IDEA WAS TO APPLY MAINLY THE mOATATION CELL ON THE WATER LOOPS &IG SHOWS DIFFERENCE IN FOAMING EFFECT BETWEEN NON mOATING WATER BLUE CURVE AND mOATED WATER PINK CURVE AND HIGH FOAMING EFFECT OF THE mOATATION REJECT GREEN CURVE )N 3!3 SATURATED CLOSED CIRCUIT WITH HIGH FOAMING ISSUE THE GREEN CURVE COULD BE THE DAY TO DAY MILL SITUATION &IG SHOWS SOME RESULTS OBTAINED ON -!+ # VERSUS CONVENTIONAL TECHNOLOGIES
Fig 10 MAK C efficiencies
7HEN IN A PROCESS AS WE HAVE DEMONSTRATED BEFORE WE WANT TO REMOVE CONTAMINANTS THAT NONE OF THE MACHINE INSTALLED ARE ABLE TO REMOVE THEM AND FOR CLOSE WATER CIRCUIT PROCESSES WE ARE CREATING SATURATION EFFECT !ND CONTAMINANTS CAN ONLY GO TO THE PAPER MACHINE AND GENERATE DEPOSIT OR WITH THE EFmUENT WHICH COULD BE A SMALL AMOUNT WHEN CIRCUIT IS CLOSED $EPENDING ON WATER CIRCUIT OPENING YOU CAN MULTIPLY BY TO WHAT IS REALLY COMING IN AS CONTAMINATION
Fig 9 results of foaming dropping when floating process water by removing SAS 26 papermiddleast
/NE OF THE SOLUTION FOUND TO IMPLEMENT mOATATION PROCESSES IS TO CREATE WHAT WE CALL THE KIDNEY CONCEPT AS SHOWN ON lG
Fig 11 Saturation phenomena demonstration for closed circuit
Fig 12 Kidney concept using MAK C
4. Conclusions 4RENDS IN PACKAGING CLEARLY SHOW NEEDS TO lND ADDITIVE WAYS TO REMOVE CONTAMINANTS AND MAINLY MICRO STICKIES 3URFACE !CTIVE 3UBSTANCES ASH AND -INERAL /IL .EW -!+ # AND NEW #TP PATENT GRANTED TO +ADANT GIVES HOPES AND POSSIBLE SOLUTIONS TO IMPROVE PACKAGING LINE OPERATIONS WHILE KEEPING ADDING MASS REJECTS TO A LOW LEVEL