Paper Mart Emagazine Aug-Sep Issue 2021

Vol.22 No. 03

August-September, 2021

PACK-A-BOO Paper Packaging an Answer to Sustainability Issue...24

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CONTENTS August-September, 2021, Paper Mart

PACK-A-BOO Paper Packaging an Answer to Sustainability Issue

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PACKAGING SPOTLIGHT

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Gayatrishakti Paper & Boards: Believing in Technology and Dedicated Workforce

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“We have made a huge investment in upgrading the plants and using the latest technology has helped the company to increase the production in both the plants from 1,86,000 MTPA to 2,44,000 MTPA.”

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Kuber Packaging Industries: Providing Eco-Friendly Alternatives to Single-Use Plastic Disposables through Ekopak

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“The core strength of the brand is the product range which is ‘backyard’ compostable within 90 days making it optimal to replace single-use plastics.”

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Shree Krishna Paper Mills: Innovating Quality Products to Meet the Growing Demand “In packaging, the future will be developing high tear factor packaging papers with value-added solutions. I feel the industry will change from using burst factor terms to tear factor terms, having high tear is more important than having high BF.”

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Retention and Drainage Improvement with AI/IoT Based Closed Loop Control HABER has done a detailed system survey followed by lab evaluation using Britt Dynamic Jar and Drainage Tester for screening a suitable program keeping furnish and achine configuration in mind.

99 Kemira Glyoxalated Polyacrylamide (GPAM) Multi-Function Development in APAC Pulp & Paper Industry

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Kemira spent many years developing Glyoxalated Polyacrylamide (GPAM) product and application technologies, aiming to break through existing wet end limitations and build up a more robust system against variations.

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NEWS

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Gayatrishakti Paper & Boards:

Believing in Technology and Dedicated Workforce “We have made a huge investment in upgrading the plants and using the latest technology has helped the company to increase the production in both the plants from 1,86,000 MTPA to 2,44,000 MTPA”

G

ayatrishakti Paper & Boards Limited (GSPBL), started in 1996, is a leading manufacturer of a range of premium grades of packaging boards and kraft paper. Their products are made out of 100 percent recycled waste paper and are completely biodegradable. The company sets out to undertake various innovations in both the product-development side as well as in manufacturing processes on a consistent basis. Presently, GSPBL has invested in developing a 500 TPD brandnew pulp mill from the world-renowned 'Kadant' technology implemented and is currently under final trial-run.

(L-R) Mr. Nikhar Agarwal, Executive Director and Mr. Gajendra N. Agarwal, Managing Director, Gayatrishakti Paper & Boards Ltd.

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In an interview with Paper Mart, Mr. Gajendra N. Agarwal, Managing Director, Gayatrishakti Paper & Boards Ltd., enlightens us about the business journey of the company, the manufacturing capabilities along with the infrastructure of their production facilities at Vapi and Sarigam in Gujarat and the enabling factors to process a

I•N•T•E•R•V•I•E•W wide range of packaging board grades.

Further, he also outlines the trends in the packaging industry and the future plans of the company.

Paper Mart: Could you please take us through the journey of Gayatrishakti Paper & Boards Ltd. and the notable milestones so far?

Gajendra N. Agarwal: Gayatrishakti Paper and Boards Ltd. started its business as a packaging paperboard manufacturing company with its head office in Mumbai and two manufacturing facilities in Vapi and Sarigam, Gujarat. The company was founded by me in September 1996. Mr. Nikhar Agarwal, the second-generation in the business, is also into the day-to-day business of the company and is currently the Executive Director.

The company manufactures premium quality duplex boards and kraft paper from 100 percent recycled waste paper pulp and has an installed capacity of 1,08,000 MTPA and 1,44,000 MTPA. In fact, we are one of the leading manufacturers of duplex boards and kraft paper in India. We constantly upgrade our manufacturing facilities with the latest technologies in order to manufacture superior quality duplex boards and kraft paper.

PM: Please describe the manufacturing capabilities of the company along with an overview of the infrastructure of the unit. Has

There has been a growing interest from all stakeholders to make packaging more sustainable and environmentfriendly… The growth of this (paperboard and packaging) market is dependent on the demand for folding cartons and corrugated boxes products in the ecommerce packaging sector.

there been any expansion at the company in the recent past?

GNA: Initially, the company had one manufacturing facility of the duplex board with a production capacity of 96,000 MTPA and product range from 230 GSM to 500 GSM. The management felt the need to enter in kraft paper packaging segment and thus, the company established a kraft manufacturing facility in 2013 at Sarigam, Gujarat. The project was completed within a span of 18 months and started commercial production in June 2015 with a production capacity of 90,000 MTPA. At the kraft facility, we manufacture kraft paper in the range of 18 BF to 35 BF. It is one of the largest kraftproducing plants in India on a single machine with more than 12,000 MTPA. The company has enhanced infrastructure at both the manufacturing facilities at Vapi and Sarigam. The use of the latest technology at both the manufacturing facilities helps in improving the quality of the finished

product. The company has a 4MW captive power plant at both facilities.

We have made a huge investment in upgrading the plants and using the latest technology that has helped the company to increase the combined production capabilities in both the plants from 1,86,000 MTPA to 2,44,000 MTPA. In the future, we intend to increase the production capacity in both plants from 2,44,000 MTPA to 3,00,000 MTPA by FY23.

PM: Kindly describe the product portfolio of Gayatrishakti Paper and Boards. Also, shed some light on the kind of clientele, i.e. the different brands served by the Company.

GNA: Our Company manufactures duplex board and kraft paper at its manufacturing facilities at Vapi and at Sarigam in Gujarat. The range of the duplex board is from 230 GSM to 500 GSM and the range of kraft paper starts from 18BF to 35BF. We sell the product

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In the future, we intend to increase the production capacity in both the plants from 2,44,000 MTPA to 3,00,000 MTPA by FY23.

through a network of dealers and distributors. Due to our leverage on technology, the quality of our product has been consistent over the years and it has been widely accepted in the domestic and international markets.

Our end-users are leading companies in the segments such as – MNCs, FMCGs, pharma, and e-commerce players.

PM: Outline the factors which enable you to process a wide range of grades in packaging boards, while ensuring cost efficiency and enhanced product quality.

GNA: Investment in the right technology and competent workforce are the key factors that enable us to process a wide range of grades in packaging boards with cost eff iciency and enhanced product quality. We have the best automation system from renowned vendors in the industry. We also have a competent and loyal workforce and executives at all levels that are well trained for their role and they are given individual responsibilities in their respective areas.

PM: Rising consumer awareness and adoption of sustainable materials have rapidly increased in the past few years. How would you describe the impact of this trend on the Indian paper and paperboards market?

GNA: Consumers' attitude towards minimising the use of plastic has changed the attitude of the paper and packaging industry over the last decade. With the ban on plastic by governments and public authorities

around the world, the demand for p a c k a g i n g p a p e r h a s i n c re a s e d significantly over a period of time and is expected to increase at a steady pace in the future. There has been a growing interest from all stakeholders to make packaging more sustainable and environment-friendly and paper is considered as the most environmentfriendly material available.

Impact on Indian paper and packaging industry The packaging industry in India is growing rapidly, and it is spanning across various end-user segments such as food and beverages, healthcare, hygiene, and home care, among others. Strong favourable demographics aside, factors such as growing disposable income levels, increasing consumer awareness and demand for processed food, and the multinational giants taking rapid strides in the food, beverages, ecommerce, and pharmaceuticals space, are the key drivers impacting the growth of paper and paperboard packaging industry. The growth of this market is dependent on the demand for folding cartons and corrugated boxes products in the ec o m m e r c e p a c k a g i n g s e c t o r.

Moreover, the market is segmented by the product and end-user verticals. Its end-user segment is further segmented by food, beverage, healthcare, personal care & household care, hardware & electrical products, other industries.

PM: Describe your initiatives for attaining superior quality, and enhancing efficiency in the overall production operations GNA: We have always believed in adopting the latest technology for attaining the superior quality of both the products viz. coated paperboard and kraft liner board. Our company has continuously undertaken various innovations from time to time in both the products and manufacturing p ro ce s s e s a n d h a s s u cce s s f u l ly

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implemented them so as to provide premium quality in the packaging market as well as enhance efficiency in the production operations.

Various technologies such as the introduction of blade coating in the coated paperboard to get the highest printing results, adding a hot disperser system in the kraft plant to make the final product of kraft paper specks- and smell-free and adopted jet cooking system for starch spray in kraft has made possible to provide the superior quality. Presently, our company has invested in developing a 500 TPD brand-new pulp mill from the worldre n ow n e d ' K a d a n t ' te c h n o l o g y implemented and is currently under final trial-run. This is projected to further enhance the capabilities in attaining more superior quality and enhancing efficiency in the overall production operations in the kraft division of the company.

PM: E-commerce packaging is swiftly growing at an enormous pace within the packaging industry – in this respect, how rigid is packaging positioned in the industry?

GNA: The retail e-commerce packaging market is growing promisingly, with the rapid growth in the online shopping ecosystem. Moreover, changing lifestyles of people led by rapid urbanisation, mainly in the developing regions, augment the d e m a n d f o r re t a i l - e - co m m e rce packaging solutions. The increasing consumption of retail-e-commerce packaging materials fosters the retail ecommerce packaging market growth.

With the spurring rise in the overall retail industries worldwide, the market is projected to garner immense gains over the next few years.

The Indian e-commerce packaging market was valued at USD 13.8 million in 2020, and it is expected to reach USD 1109.26 million by 2026, registering a CAGR of 13.8 percent during the period of 2021-2026. Owing to the rising

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Presently, our company has invested in developing a 500 TPD brand-new pulp mill from the worldrenowned 'Kadant' technology… This is projected to further enhance the capabilities in attaining more superior quality and enhancing efficiency in the overall production operations in the kraft division.

population, increasing income levels, changing lifestyles, and growing economy, the demand for e-commerce packaging is growing in India. The country is focusing more on sustainable solutions, which is increasingly becoming a business imperative. With the growing awareness, the requirement for eco-friendly and sustainable packaging is steadily on the rise. With several billion parcels delivered every year, the threat of packaging waste is increasing due to which, the need for recyclable packaging material is on the rise.

Many e-commerce companies are focusing on sustainable packaging solutions to reduce plastic waste and move toward paper-based packaging.

Corrugated boxes are very common and widely used packaging materials for the e-commerce industry in the apparel segment, as the material is very strong and highly durable. Accelerated

demand for packaging boards for online purchases is expected on account of the COVID19 pandemic. The market for packaging boards is likely to grow 9-10 percent annually in India, compared with around four percent globally.

PM: What are the future plans of Gayatrishakti Paper & Boards Ltd? GNA: At present, the company is focused on increasing the production capacity and as a result thereof, the current installed capacity of the company is 2,50,000 MTPA of both coated paper board and kraft liner board. The company has already undertaken the CapEx program to enhance the capacity to 3,00,000 MTPA where the major capacity enhancement is proposed in the Kraft division.

Developing a 500 TPD brand new pulp mill from the world-renowned 'Kadant' technology is under final trial-run so as to enable us to get better quality with

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required quantum more pulp presently which will further add in attaining more superior quality and enhancing efficiency in the overall production operations in the Kraft division of the company. The company is also in the process to develop premium products in near future to cater to the increased demand for products, mainly 'white top kraft liner board' and 'kraft pulpboard'.

The company has an inbuilt manufacturing facility to produce uncoated white top kraft liner board and is shortly going for trial-run production so as to get a response from both domestic and international markets. In addition, the company is also planning for manufacturing of partial quality of va l u e - a d d e d p ro d u c t v i z . k ra f t pulpboard mainly required in the premium segment of corrugated boxes.

Presently, such kraft pulpboard is being manufactured in very small quantum in India and the balance requirement is being met through import sources.

Further, the company aims to replace imported kraft pulpboard with Indian kraft that will match international standards and quality to promote domestic product usage in India. Both the products are mainly used in the premium segment of packaging and the demand in both domestic and international markets is growing gradually.

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Shree Krishna Paper Mills:

Innovating Quality Products to Meet the Growing Demand In packaging, the future will be developing high tear factor packaging papers with value-added solutions. I feel the industry will change from using burst factor terms to tear factor terms, having high tear is more important than having high BF

Mr. Naynesh Pasari, Director, Shree Krishna Paper Mills & Industries Ltd.

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S

hree Krishna Paper Mills & Industries Ltd. (SKPMIL) was established in the late 70s. The paper division was set up in the year 2004 and since then, SKPMIL has been using recycled fiber and virgin pulp to manufacture several varieties of industrial and specialt y p ap e rs i n cl u d i n g n e w s p r i n t , e l e c t r i c a l insulation kraft paper, interleaving kraft paper, colour kraft paper and absorbent kraft paper. The company recently entered in the packaging sector with kraft paper for carry bags. In an interaction with Paper Mart, Mr. Naynesh Pasari, Director, Shree Krishna Paper Mills & Industries Ltd. talks about the company's achievements, manufacturing capabilities, product portfolio and R&D efforts.

I•N•T•E•R•V•I•E•W Paper Mart: Could you present a brief overview and significant achievements of Shree Krishna Paper Mills?

Naynesh Pasari: Shree Krishna Paper Mills has been in the industry for more than 45 years. It was started by my father in the late 70s. Since then, the company has been growing together with its customers, innovating and delivering quality products to meet the growing global demand for different types of paper.

We used to primarily produce C1S and C2S paper for which we used to procure base paper and then do value addition of coating on it; we were also the first company in India to introduce and manufacture thermal paper. We give a lot of priority to R&D, and innovation and that's now embedded in the company's DNA and culture.

The biggest achievement has definitely been the introduction of thermal paper, back in the 1990s. SKPM does not believe in turnover or profits as achievement, our biggest achievement is when our consumers give us repeat orders.

PM: Describe the infrastructure, the product portfolio, the manufacturing capabilities, and the machinery installed at your facility. Has there been any upgradation or capacity expansion in the recent past?

NP: In the early 2000s, we closed our Bahadurgarh division which was the coating unit producing C1S, C2S, and thermal paper because of electricity issues and unviability in terms of smallscale industry. At the same time, we invested in backward integration by setting up paper manufacturing unit in Rajasthan. The idea of the company was to have our own papermaking capability and then do the coating on it and serve the customers.

We had planned this plant as agrobased, but unfortunately, we couldn't get the required license for it and also learnt that agro units leave a lot of

environmental waste. So we went for waste paper-based manufacturing set up. We have almost 90 acres of land available for future expansion. If the situation becomes conducive, we look forward to utilizing that land.

We have the capability of manufacturing approximately 60,000 TPA in the GSM range of 30 to 150. Various grades are manufactured under one roof. We have one paper machine and one coating machine. The paper machine has a two-stage deinking plant from Lamort, France and the machine itself is from the USA. Our coating machine is India's first and only manufacturing machine which has the three-stage coating– first stage, second stage, and back-barrier along with soft-nip calendar online, with almost 700 tonnes per month of manufacturing capability on the coating machine (offline coating).

PM: You have launched kraft paper for carry bags this year; tell us more about the product along with the USPs. NP: Initially, we had no idea how to make kraft paper for carry bags and started with 5 tonnes. BF is one of the parameters but not the only parameter in this. If you want to give good quality to the product, then you need to have minimum GSM variation, minimum moisture variation, high-tear factor, relatively speck-free paper, less dirt count, and very less shade variation, so, it's a complicated product to manufacture and supply consistently and that is exactly where our USP lies.

With our efforts, we are indirectly supplying our products to KFC, Taco Bell, and other QSR brands that are using our papers through converters.

PM: Now that you have told us that you basically manufacture from recycled papers, do you face any challenges while procuring waste paper?

NP: Making 'wealth' out of 'waste' definitely comes with a lot of chal-

After undertaking extensive R&D activities, we developed shuttering paper which has been a grade that we have developed in house using our own R&D and trials. We believe in creating products using our own research and not copying other mills.

lenges. Unfortunately, India is highly dependent on imports of waste paper.

The availability of pulp or waste paper is limited in our country but mills are in huge numbers. There are approximately 600 paper mills, out of which 70 percent are recycled paper-based.

People set up their mills but the planning or strategy required for waste paper in our country is not something that anyone wants to do. It is a totally unorganized market. We are still living in the age when most people simply burn waste paper or pack food in it. India is a fibre short country as neither we have pulp nor high strength waste paper. Hence, we are always dependent on imported fiber to run the 450 odd recycled paper mills our country is operating. People do not follow the practice of segregating the dry waste and wet waste in our country and this is a major drawback.

However, people now, at least, have the basic fundamental knowledge on the importance of recycling. So, that is the positive side.

PM: Tell us about your new product and R&D efforts.

NP: After undertaking extensive R&D activities, we developed shuttering paper which has been a grade that we have developed in house using our own R&D and trials. We believe in creating products using our own

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We give a lot of priority to R&D, and innovation and that's now embedded in the company's DNA and culture. We never copy any other mill's technology as we believe in one thing: Develop something on your own, cross that journey, stand on your own feet – copying others is easy but the real satisfaction lies in being original. research and not copying other mills, which recently has been the case with some mills who have simply just copied our technology. For any paper, you need to keep in mind the quality, cost factor, and the process. We are sure that because of our sincerity, co n s i s te n t e f fo r t s i n R & D, o u r adaptability to new things and acceptance to change, we have been able to create this product out of scratch with our own technology.

Further, we are in the R&D stage of print-based decorative laminate paper.

As we are already manufacturing shuttering paper, this is the complementary industry. So, this was the right product for us to do R&D upon. We have reached a situation in this development where we are confident that we will be able to make it. In this also we have not taken any help from anybody or copied any mills technology. It is our own painstaking research and development.

PM: Could you please shed some light on the various grades of food grade paper manufactured by SKPMIL and what is the market scenario of such papers?

N P : Va r i o u s ce r t i f i c a t i o n s a r e required to be able to produce food

grade papers which can be greaseproof paper or carry bag paper. There are certain factors which have to be especially focused for producing such papers.

added solutions, whether it is the normal paper or coated paper. The value-added items in packaging are going to be a very big role player in the coming years.

The first thing starts with the quality of water - the kind of investments you have made for water management at the mill, to recycle it and so on, because the paper is ultimately made from water. The second thing is that the food-grade kraft paper should be odour free. Paper should be free from heavy metals, chloroforms, there are certain other chemicals which when come in contact with food create an impact on the food. Over a period of time, we have put a lot of effort in this process.

PM: Any improvement in terms of technology at your mill?

PM: What has been the impact of the pandemic on your company?

NP: I think everybody has been affected by the pandemic in some way or the other. The real answer lies in how fast one can absorb and accept the change, and take corrective actions. So, thankfully, we have already taken corrective actions. What lies in the future is still a grey area for everyone; however, I am confident that packaging will never die. In packaging, the key is how fast one can innovate with value-

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NP: In technology, if we say asset-wise or machinery-wise, we have always been investing. We have purchased some equipment for the pulp mill, out of which a few have been imported and the remaining has been purchased from domestic suppliers. The paper industry is a highly capital-intensive industry. So, if you want to keep playing the game, you have to keep investing.

PM: Anything else that you would like to add to the interaction?

NP: I think, overall, the industry has been going through a very challenging time because raw material remains uncertain and the prices are at an alltime high – be it raw materials or logistics. India has to become selfsufficient in terms of generating and consuming waste. How to give the same quality finished goods to the consumer with quality waste paper that is never consistent and higher input costs is the challenge the industr y is going through.

MITTHANJE E G ROUP E S TD . 1 9 3 3

Leading Exporter of All Paper & Paperboard Grades of Indian Mills Incorporated in 1948, Mitthan Lal Group is a fourth-generation business that sources globally and exports all grades of prime papers and paperboards across the world.

P R O V I D I N G PA P E R S O L U T I O N S G L O B A L LY

Corporate Office:

Sales Office:

E-mail

C-107, Sector - 2, Noida - 201301, Uttar Pradesh, India Tel: +91 120 4659700

234, Chawri Bazar, Delhi - 110006, India Tel: +91 11 46449999

vj@mlmindialtd.com

www.mlmindialtd.com

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(L-R) Mr. Uchit Gupta and Mr. Sanchit Gupta, Directors at Kuber Packaging Industries Pvt. Ltd.

Kuber Packaging Industries:

Providing Eco-Friendly Alternatives to Single-Use Plastic Disposables through Ekopak The core strength of the brand is the product range which is 'backyard' compostable within 90 days making it optimal to replace single-use plastics.

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E

kopak is a brand of Kuber Packaging Industries Pvt. Ltd. created with the thought of making the most sustainable packaging in the most ethical way possible. Made from sugarcane pulp, the products are touted to be 100 percent natural, compostable, biodegradable and toxic free. In a conversation with Paper Mart, Mr. Sanchit Gupta and Mr. Uchit Gupta, Directors at Kuber Packaging Industries Pvt. Ltd. presents an overview of the brand, views on the compostable tableware market in the country, and future plans for the company.

I•N•T•E•R•V•I•E•W Paper Mart: Could you please present an overview of Ekopak and the objectives behind establishing the brand?

Sanchit Gupta: Founded in 2020 by Uchit Gupta and me, Ekopak takes pride in being the first sustainable tableware manufacturing brand in S o u t h I n d i a . A n e a r t h - f r i e n d ly tableware brand under Kuber Packaging Industries, we are the only ones to manufacture and provide all eco-friendly alternatives to single-use plastic disposables mainly tableware in-house. The core reason behind setting up the brand was the environmental impact that plastic was causing on our mother earth. Plastic pollution costs USD 13 billion in economic damage annually, which is a very frightening number for our future survival. Ekopak is a green-field company and ensures to drive the market by offering certified moulded fiber alternatives to brands to eliminate

We aim to add a new moulded fiber product every month to meet the market demands and help replace plastic whenever possible.

and eradicate the usage of single-use plastics.

PM: Kindly guide us through some of the key strengths of the brand and your product offerings.

Uchit Gupta: Ekopak's moulded-fiber tableware range is designed and manufactured in an ISO Certified facility located in Hyderabad. The core strength of the brand is the product range which is 'backyard' compostable within 90 days making it optimal to

replace single-use plastics for a cleaner and healthier planet. Ekopak manufactures more than thirty food-grade sustainable products all under one roof to maintain efficiency and meet our utmost quality parameters. Our b i o d e g ra d a b l e ra n ge co m p r i s e s bagasse plates, bowls, trays and containers, wooden cutlery, paper straws, paper cups and unbleached tissue papers. We are a one-stop-shop!

PM: What is the current market presence of the company – both globally and domestically? Do you plan to expand your market presence in the near future?

SG: Ekopak takes pride in spreading sustainability across 14 cities domestically covering all Tier-1 cities, and currently exporting to the UAE, Europe, and the United States. But it doesn't stop here; we are expanding, in terms of distribution, production capacity, and product range. We aim to

Manufacturer of : Complete Paper Machine from conveyor to Rewinder • Duplex • Multi Layer Kraft • Kraft • Newsprint

D.S. Pulp & Paper Machinery Pvt. Ltd. D.S. Engineers Mfg.: Paper, Pulp & Cement Plant Works & office: Plot No. 5314, Phase IV, Ramol Cross Road, G.I.D.C. Vatva, Vatva, Ahmedabad - 382445.

(Rajesh Desai) +91 9825042710, 9227225579 E-mail: dsengineers_raj@yahoo.com / dspl@ymail.com

www.papermillmachineryindia.com | www.papermillindia.com

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The size of the disposable tableware market is valued at around USD 320 billion; we are estimating 10 percent of that market has shifted towards sustainable packaging options. add a new moulded fiber product every month to meet the market demands and help replace plastic whenever possible. The goal is to erase all singleuse plastics from our mother earth.

PM: Share details about the manufacturing facility – the infrastructure along with the current capacity and various measures kept in mind for maintaining product quality.

UG: Our top-of-the-class manufacturing facility spread over 75000 sq. ft. is located in Hyderabad. As mentioned earlier, we are proud to be the first biodegradable tableware facility in South India. The current capacity of the sugarcane bagasse tableware is 1680 tonnes annually. We are aiming to double up the production capacity by 2022. Quality is our utmost priority, keeping that in mind every product undergoes a 3-step quality check test, starting from the raw material to the finished product. We have a highly skilled team of QC executives that is keen on maintaining the hygiene measures as well as the top-notch quality in the segment. We are an ISO 9001/14001 certified company, and are currently on the track to claim BRC, and other international certifications.

PM: What is the current size of the sustainable disposable tableware market and the chief growth drivers of the market segment?

SG: The size of the disposable tableware market is valued at around USD 320 billion, yes you read that right.

Currently, we are estimating 10 percent

of that market has shifted towards sustainable packaging options. We see a massive opportunity in transforming the world's food industry by providing them moulded f iber packaging alternatives that are good for the planet. Plastic pollution costs the world a staggering USD 13 billion annually. Apart from the economic damages, researchers have analysed that the flow of plastic dumped into the ocean can triple in size by 2040, and by 2050, there will be more plastic than fish in the ocean. That's an alarming fact and needs to be addressed by the entire world together.

PM: From the sustainabilityperspective, the biodegradable tableware has a lower carbon footprint, how do you ensure the manufacturing process is also more energy-efficient and costefficient than non-biodegradable ones?

UG: Yes, that's absolutely right that biodegradable tableware has a far lower carbon footprint when compared to manufacturing plastic. To ensure energ y eff iciency and resources management, we have enabled a few steps such as rainwater harvesting and wastewater recycling to efficiently consume water. In terms of power, we use briquettes made out of rice husk or other agro-waste to heat up our thermic fluid heater. This year, we are adding solar panels to replace our electricity consumption.

PM: Kindly shed light on the positive steps taken by the government and what else can be done to facilitate the growth and consumption of compostable tableware in the country?

SG: Kudos to the Government of India for implementing 'No single-use plastic' rule across India commencing July 2022! This is a major breakthrough to contain plastic from being manufactured, sold or used. Initiatives like this drive brands like Ekopak to push sustainability more and spread

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awareness about the harmful effects of using plastic or any other nonbiodegradable material. Another major problem that our country faces is the plastic collection & recycling processes. It is crucial to segregate the plastic from the other waste and make sure that it reaches the recycling facility instead of the ocean or being buried in the landfill. To encourage and facilitate the growth of compostable tableware, it is evident to impose a strict penalty/ban on the single-use plastic manufacturers/wholesalers as well as to educate the citizens about the harmful effects of using plastic. We believe our entire nation needs to unify together to fight this war against plastic.

PM: Please outline the recent developments at Ekopak. What are your aspirations and future plans for the company?

UG: Ekopak, being an earth-friendly brand, is always undergoing research and development to come up with new ways to replace SUP (single-use plastic). It is our mission to provide sustainable alternatives to all SUPs whether it is disposable tableware or packaging for a product. We have recently developed compostable meal tray with lid for takeaways along with un-bleached tissue napkins.

We are always developing new singleuse eco-friendly products which are being used by all our consumers. In the coming year, we aim to establish a new automated manufacturing facility equipped with the latest technology to p rov i d e co m p o s t a b l e t a ke aw ay products for export markets. We take inspiration from our fellow brands in this field and help one another to make the world a greener and cleaner place for our future generations to come. It brings us immense pride to see multinational corporations such as Starbucks, McDonald's, Burger King, Coca-Cola, etc. switching towards sustainability. Ekopak welcomes any such company or individual to join us in this mission to eliminate single-use plastics. Go green, Go Ekopak!

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PACK-A-BOO Paper Packaging an Answer to Sustainability Issue

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ackaging is not just the technology of containing, protecting, and preserving a product but also the face value of a commodity. A creative aspect of marketing – packaging is an art that has the potential to make or break a product. Being cost-effective and highly efficient, paper is one of the most common materials of packaging. Even if we talk about sustainability and ecofriendliness, paper packaging has it all - it's recyclable, reusable, and made from renewable natural resources.

Sturdy but versatile, paper-based packaging products can be used in many forms such as wrapping paper, paper shreds, paper bags, paper sacks, mono cartons and corrugated boxes. The latest innovations in design and quality of the materials have made paper & paperboard packaging a

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practical choice for any brand. Known to provide convenience as well as visibility, products can showcase their distinctive packaging and graphics to tell a brand's story.

Impact of the ‘New Normal’ As per a report by McKinsey & Company, more than twothirds of US consumers worry about contracting COVID19 from food packaging, which has added new pressure on the food companies. According to a study by researchers from the Indian Institute of Technology (IIT) Bombay, the novel coronavirus may survive for a lesser time on porous surfaces such as paper than on impermeable surfaces like glass and plastic. As a result, food and beverage companies are inclining towards paper and paperboard packaging.

With this trend, there could be plenty of room for enhanced packaging designs as well.

“Consumers have become used to various conveniences during the pandemic, and these will not go back to the old normal (flexible work hours/work from home, online shopping/delivery services, virtual meetings/reduced travel for work, etc.). All of these have an impact on the kind of packaging needed, how branding is to be done, etc.,” said Mr. Harsha Paruchuri, Director at Pragati Offset while talking about the impact of the pandemic on the packaging sector. As consumer intent to shop online continues to increase, the demand for packaging boards is set to rise in near future. “The market for packaging boards is likely to grow 9-10 percent annually in India, compared with around four percent globally,” said Mr. Gajendra N. Agarwal, Managing Director, Gayatrishakti Paper & Boards Ltd.

A Sustainable Alternative to Plastic Today, consumers widely view paper as a more environment-friendly alternative to plastic. Commissioned by Two Sides in 2020, a European consumer preferences survey concluded that 62 percent of consumers see paper and cardboard packaging as better for the environment. The United States is one of the largest paper-producing countries and around 62 percent of the paper produced in 2018 was used for packaging, primarily corrugated boxes.

Paper relatively has a higher recycling rate than other packaging materials as it can be re-pulped. As per a report published by the United States Environmental Protection Agency in 2020, it has a 68 percent recycling rate compared to 9 percent for plastics. According to ResearchAndMarkets.com, the global paper recycling market is estimated to be USD 45.5 billion in 2020 and is expected to reach USD 56.2 billion by 2025, growing at a CAGR of 4.3 percent.

An increasing number of cafes in India have replaced plastic cups with paper cups. The paper cups market size in India reached INR 2,139 crore in 2020 and expects to exhibit strong growth during 2021-2026, as per the latest report by IMARC Group. Fast-food chains and restaurants are also switching from single-use plastic tableware to biodegradable tableware and recyclable paper cutlery. For instance, McDonald's claims to source 99.6 percent of its paper food packaging from the recycled or sustainable fiber. “Paper packaging accounts for more than 80 percent of all packaging, including over 50 items of paper bags, paper cups, paper straws, and paper boxes,” said Rajeev Ranjan, COO, Connaught Plaza Restaurants Pvt. Ltd. Uttar Pradesh-based Yash Pakka Ltd. is being marketed at restaurants for its comprehensive line of bagasse tableware products. Mr. Shailesh Singh, Paper Sales Head of the company feels that the Government of India's recent

circular to ban single-use plastics may become a driving force and an opportunity to push sustainable products to the consumer market.

“The size of the disposable tableware market is valued at around USD 320 billion. We are estimating 10 percent of that market has shifted towards sustainable packaging options,” said Mr. Sanchit Gupta, Director of Kuber Packaging Industries Pvt. Ltd. that manufactures ecofriendly tableware under the brand Ekopak.

Not just food and beverage companies, even FMCG and luxury companies have started focussing on eliminating plastic in packaging. After launching the first paper-based tubes under La Roche -Posay brand, L'Oréal has announced that it would soon use cardboard bottles developed by the start-up Paboco. Meanwhile, Procter & Gamble has unveiled its first paper bottle for Lenor.

Summing Up the Success Story According to Valuates Reports, the global paper and paperboard packaging market size is expected to reach USD 224.74 billion by 2027, from USD 189.32 billion in 2020, at a CAGR of 2.9 percent during 2021-2027. A recently released report by Reportlinker.com projected the paper and paperboard trays market to reach USD 7,319.26 million by 2028 from USD 4,942.09 million in 2021; registering a CAGR of 5.8 percent from 2021 to 2028.

Seeking to make India single-use plastic-free by next year and deal with the menace of huge uncollected plastic waste across the country, the centre has recently notified a ban on single-use plastic items from July 1, 2022. With this announcement, every sector is gearing up to implement economical, plastic-free packaging/eco-friendly options with the paper being one of the most popular alternatives to plastics.

“Major factors which will drive the demand going forward include e-commerce, industries which will benefit from PLI scheme, food processing industry which will also benefit from agricultural reforms announced by the government, FMCG and consumer durables industries which will benefit from a rise in discretionary income of the Indian masses,” said Mr. Kirit Modi, Chairman & Managing Director, Horizon Packs Pvt. Ltd. and President Emeritus of Indian Corrugated Case Manufacturers Association (ICCMA).

“Huge investments in the food processing, personal care, and pharmaceutical end-user industries are creating scope for expansion of the packaging market,” added Mr. Nikhil Borkar, Director, Borkar Packaging Pvt. Ltd. while commenting on the current market scenario of paper packaging in India. Keeping up with the evolving trends, paper packaging is going to be the next big thing in the future!

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P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

Horizon Packs: Corrugated Box Industry Prepared to Meet Increasing Demand in Tandem with India’s GDP Growth

We have corrugated box manufacturing plants at nine different locations with the paper converting capacity of 2,40,000 TPA.

Mr. Kirit Modi, Chairman & Managing Director, Horizon Packs Pvt. Ltd. and President Emeritus of Indian Corrugated Case Manufacturers Association (ICCMA)

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lending the art and science of packaging i n n o v a t i v e l y, H o r i z o n Pa c k s P v t . L t d . endeavours to create packaging that stands out as an example of excellence. From paper to boxes, the company's expertise encompasses the entire gamut of corrugated packaging. With the vision of having a presence Pan-India with advanced infrastructure for maintaining sustainable growth, Horizon Packs aims to deliver operational excellence and non-compromising quality by providing optimal packaging solutions. Paper Mart got the opportunity to interact with Mr. Kirit Modi, Chairman & Managing Director, Horizon Packs Pvt. Ltd. and President Emeritus of Indian Corrugated Case Manufacturers Association (ICCMA) and know about his company and its state-ofthe-art machines, his views on the current market situation after the pandemic and key expectations from the paper mills.

Paper Mart: Tell us about your company and manufacturing capabilities — monthly paper converting capacity and the key technologies you have in-house.

Kirit Modi: Horizon Packs Pvt. Ltd. has corrugated box manufacturing plants at nine different locations with the paper converting capacity of 2,40,000 TPA. All of our

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plants have automated corrugated lines with in-house state-of-the-art converting machines. We have been servicing a vast marquee clientele on a Pan-India basis for the past three decades. We cater right from the fastmoving goods category to white goods (electronics, household appliances) to foods & beverages. We cover most of the multinationals having a presence in the Indian market.

PM: What challenges do you face with regard to the quality of paper & paperboard? Please share some of your key expectations from the paper mills.

KM: Although most of the kraft paper mills have certainly improved their quality over the last few years, however, there are still a few issues that should be addressed by the mills. These issues are – odour in the paper, poor rewinding quality, and so on.

Our key expectations from the paper mills include: l

An uninterrupted and seamless supply of smell-free paper.

l

Excellent rewinding can impact better runnability on high-speed lines.

l

Commitment to provide committed linear meterage which must be mentioned on the paper reels.

P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

Our key expectations from the paper mills include an uninterrupted and seamless supply of smell-free paper, excellent rewinding that can impact better runnability on high-speed lines, commitment to provide committed linear meterage which must be mentioned on the paper reels and standardisation of paper GSM and other parameters.

l

Standardisation of paper GSM and other parameters.

PM: With the 'New Normal' imposed due to pandemic, what is the current market situation and what are your projections for the future?

off the scale. Actually, Chinese paper mills turned to Indian paper mills to import large quantities of kraft paper, which impacted the availability of kraft paper for the Indian corrugated box makers. Moreover, the overall export opportunity of kraft paper for Indian kraft paper mills affected the domestic supply situation in the market.

With the onset of the pandemic, more and more consumers preferred online shopping which has boosted the growth in e-commerce. As a result, the demand for ecommerce packaging is also furthering and is likely to rise in the coming future.

All these factors in conjunction have impacted the demand and supply dynamics and their combined impact has affected the pricing and availability of the inputs for the paper and paper packaging industry.

Structural Changes The emergence of integrated players is set to transform the packaging sector. Also, in the recent past, we have witnessed a number of large corporates entering the corrugated box industry. A number of FMCG brands, ecommerce majors, fashion companies, and many more across various industries are switching to sustainable packaging.

KM: The advent of the pandemic and the start of a 'New Normal', as we call it, have brought with it a series of unprecedented changes in the way businesses, across a number of industries, function. With regard to the paper and paper-based packaging industry, there are four chief micro-level changes which can be categorised as — fundamental changes, structural changes, incremental/directional changes and technology-led transformations.

Furthermore, there has been a major consolidation wave – i.e. Mergers & Acquisitions, that's been going on. This is likely to have a profound effect on the packaging industry's growth prospects and long-term outlook.

Fundamental Changes

Directional/Incremental Changes

In particular, there has been significant volatility in the pricing of all commodities including major raw materials like - paper, coal, oil, starch, etc. This is significantly disrupting the overall production costs in the industry.

In recent years, there has been a notable emphasis in product design to use lesser material to make lightweight packaging materials. The light-weighting package material is a long-term gain both from an economic and environmental perspective and it is going to be a key trend in the future.

Also, owing to the ban on the import of waste paper and old corrugated containers in China from January 1 this year, the availability and pricing of kraft paper has been

In the paperboard packaging industry, the demand for finer flute grades is well-positioned for an increase in market growth owing to its potential for revolutionising both corrugated containers and folding cartons.

There has been a heightened focus on the environmental, social and governance (ESG) measures. Traditionally, packaging converters have played the role of the compliant supplier to their larger and more powerful brand-owning customers. However, in the current scheme of things, manufacturers are emphasising recycling, research, and implementation of innovative methods that can make a difference in the long run. This can be accomplished by adopting the practices of a circular economy and integrating processes that address waste prevention.

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P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

With regard to the paper and paperbased packaging industry, there are four chief micro-level changes which can be categorised as – fundamental changes, structural changes, incremental/directional changes and technologyled transformations.

With the emergence and rise of new formats in retailing and the evolution of modern retail, modern-day consumers are increasingly looking for a shopping experience defined by value for money as well as sustainability. Here, the role of paper-based packaging comes into play. We are on the verge of a packaging renaissance in which new recyclable and compostable packaging materials are projected to permeate the market in the future.

Technology-led It should be highlighted that with the emergence of the “new normal”, automation in the packaging industry, in particular, the application of high-end, sophisticated machinery has increased. The present pace of technological development is projecting profound changes. To support this growth, the packaging manufacturers are continuing to utilise improved technologies to provide added value to the end-users.

Additionally, the advancement in digital printing technologies and their immediate impact on the packaging industry marks another significant evolution in the paper-based packaging industry.

The use of functional coatings offers paperboard packaging improved water barrier, deep-freeze applications as well as excellent print receptivity. It can also enhance the aesthetics of the packaging. The demand is for high-performance and sustainable coating in paper and paperboards.

Also, the concept of 'Green Energy' is of crucial importance for the paper-based packaging industry.

Since there are environmental concerns associated with power generation from non-renewable sources, it is high time that the use of renewable power, i.e. power from bio-based, renewable sources, increases in the paper mills and packaging units. It will enable the industry to be more energy-efficient and sustainable.

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PM: Please share your views on the market trends and the demand drivers.

KM: At present, the corrugated box industry has been facing a sea of challenges in various areas owing to factors such as massive paper price hikes and a rise in the cost of other inputs as well.

Recently, we have witnessed a great surge in the price of coal which is the main source of energy for paper mills. Subsequently, this has led to an evident increase in the overall production costs of paper mills. Thus, the energy crisis has had a huge impact on corrugated box manufacturers. Also, the price of imported waste paper has increased substantially for many reasons including almost a seven-fold increase in the global container freight charges. All things considered, it can be said that the huge upward price trends in a number of inputs and resources for the corrugated paper industry have dealt a massive blow.

Unless box makers are given matching paper price hikes as well as an increase in conversion cost by the users/brand owners, the industry will face difficulties to survive.

As regards market trends and demand drivers, the corrugated box industry is well-poised and prepared to meet the increasing demand in tandem with India's GDP growth. Major factors which will drive the demand going forward are: l

E-commerce

l

Industries that will benefit from the PLI scheme announced recently by Govt. of India

l

Food processing industry which will also benefit from Agricultural reforms announced by the Govt. of India

l

FMCG and Consumer Durables Industry which will benefit from a rise in Discretionary Income of the Indian masses

P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

Borkar Packaging: Demonstrating Latest Technology with Hi-Tech Machinery and Equipment

With eight plants across India, we convert approximately 12500 tonnes of paper per month.

Mr. Nikhil Borkar, Director, Borkar Packaging Pvt. Ltd.

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orkar Packaging Pvt. Ltd. has been providing packaging solutions for the last seven decades. It is one of the largest packaging companies in India that is involved in the design, development, and manufacturing of folding cartons. The company enjoys a strong presence in almost every segment including FMCG, pharmaceuticals, foods & beverages, and consumer durables. In an interaction with Paper Mart, Mr. Nikhil Borkar, Director, Borkar Packaging Pvt. Ltd. talks about the company's converting capacity, market scenario, and criteria for future packaging requirements.

Paper Mart: Tell us about your company and manufacturing capabilities — monthly paper converting capacity and the key technologies you have in-house.

Nikhil Borkar: Borkar Packaging Pvt. Ltd. and its sister concern Suraksha Packers Pvt. Ltd. prides itself as one of the leaders in the printing and packaging industry in India for the manufacturing of all types of folding mono cartons, corrugated shippers & labels.

PM: According to you, what would be the criteria for future packaging requirements? What challenges do you face with regards to the quality of paper & paperboard?

NB: Looking at current trends, future packaging requirements will be broadly based on the following criteria: • Growing shift towards biodegradable-plastics, owing to a range of applications - PLA- Polydactyl acid is the most common bioplastics used in India; • Mono-material packaging technology for recycling packaging; • Product function ability – Product-specific packaging; • Longer shelf life and product safety; • Brand and Tamper Protection.

With eight plants across India, we convert approximately 12500 tonnes of paper per month. We provide packaging solutions by demonstrating the latest technology with hi-tech machinery and equipment, which allow us to give our customers the best product and service.

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P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

Packaging technology is changing rapidly; however as a convertor, we still face challenges in getting certain types of boards such as emulsion board, antifungal recycled board, kraft backboard, carrier board and transfer metalised board.

Packaging technology is changing rapidly; however, as a convertor, we still face challenges in getting certain types of boards such as emulsion board, antifungal recycled board, kraft backboard, carrier board and transfer metalised board.

PM: With the 'New Normal' imposed due to the pandemic, what is the current market situation and what are your projections for the future?

NB: After the COVID-19 pandemic, most developed countries have burned wastepaper or used it for landfills to avoid coronavirus spread. This has resulted in a huge shortage of raw materials for Indian paper mills. India is experiencing a chaotic situation in procuring of raw materials, due to non-inwards of wastepaper from USA & European countries. Hence, raw material prices have skyrocketed. Kraft paper and paperboard prices have increased multi-fold. Further chemicals such as ink, varnish, starch, fuel like coal, furnace oil are in short supply due to RM disruption.

Most of the mills have low throughput because of a tremendous shortage of coal and raw material. Mills are

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executing orders at spot booking rates, and we need to comply with this to avoid shortages of incoming raw material.

PM: Please share your views on the market trends and the demand drivers?

NB: The Packaging Industry in India is expected to have good growth during the period (2022-2026).

Further, the demand for packaging is growing due to the rising population, increasing income levels, changing lifestyles, increased media penetration through the internet, television, and growing economy. Moreover, it is one of the strongest growing sectors in the country.

The rapid growth of the market is primarily driven by the pharmaceuticals and foods and beverages industries.

Huge investments in the food processing, personal care, and pharmaceutical end-user industries are creating scope for expansion of the packaging market. The rise of the Indian middle class, the rapid expansion of organised retail, the growth of exports, and India's rising ecommerce sector is further facilitating growth. The food industry is expected to hold the largest share in the market. Packaged food is the fastest-growing segment in the Indian packaging industry. The demand for plastic packaging is expected to get replaced by paper packaging, as it ensures food quality, safety, and long shelf life.

The demand for plastic packaging is expected to get replaced by paper packaging, as it ensures food quality, safety, and long shelf life.

P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

Pragati Offset: Specialised in Adding Value to Packaging The quality of paper and packaging boards made in India has improved hugely over the past couple of decades.

Mr. Harsha Paruchuri, Director, Pragati Offset Pvt. Ltd.

E

stablished in 1962, Pragati Offset Pvt. Ltd. encompasses a wide array of products including paperboards, corrugated cartons, blister packs, labels and rigid boxes. It is a one-stop destination that manages a range of quality print needs beginning from structural design to production up to distribution. The company serves the full gamut of print needs – from company profiles to brochures and catalogues, coffeetable books to calendars, folding cartons and labels to luxury rigid cartons as well as point-of-sale material.

In an interview with Paper Mart, Mr. Harsha Paruchuri, Director, Pragati Offset Pvt. Ltd. talks about the capabilities of the company, the market outlook for the future, and the defining market trends of the printing and packaging segment.

Paper Mart: Tell us about your company and manufacturing capabilities — monthly paper converting capacity and the key technologies you have in-house.

Harsha Paruchuri: We are into both packaging as well as commercial printing segments. In packaging, our range of products includes paperboards, corrugated cartons, blister packs, labels, rigid boxes, and inserts/outserts. In the commercial print segment, we have a collection of products such as brochures, catalogues, leaflets and folders, calendars, etc.

Apart from having the entire process chain, i.e. pre-press, press, and post-press in-house, we specialise in adding value. This could be through finishing technologies such

34 | www.papermart.in / August-September, 2021

as foiling, embossing, holographic UV, pearl and metallic effects applied through gravure, through pre-press and print (such as our extended gamut process using 7 colours), or through anti-counterfeiting technologies, etc.

PM: What challenges do you face with regard to the quality of paper & paperboard? Please share some of your key expectations from the paper mills?

HP: The quality of paper and packaging boards made in India has improved hugely over the past couple of decades and we are quite happy with the offerings available in the market. If there are any expectations, it would be with regards to some occasional issues such as variance in the shade, coat weight, de-lamination of board layers, etc. That being said, these are some issues that we encounter very occasionally.

P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

Home delivery services for products like food, grocery, etc. are also necessitating the use of competent packaging for products that did not use branded packaging before.

PM: With the 'New Normal' imposed due to the pandemic, what is the current market situation and what are your projections for the future?

HP: Increased buying from online marketplaces has enhanced the demand for the packaging of many items.

Many companies have come up in personal care, electronic accessories, etc. who have performed well in the market since an existing physical distribution network is no longer essential to achieve success.

Similarly, home delivery services for products like food, grocery, etc. are also necessitating the use of competent packaging for products that did not use branded packaging before, for example, eggs, which were usually bought from local grocers in generic egg crates, are now being branded and home-delivered. We expect the demand for good-quality packaging as well as anticounterfeiting measures to increase in the future.

The commercial print sector has seen a drop in many of the brochures and catalogues, but certain niche segments are still doing reasonably well (these would include catalogues where the products need to be visually communicated - such as sarees and dresses, wall paints, decor, etc.).

We expect the general demand to go back up in commercial printing, though there will be segments where the

36 | www.papermart.in / August-September, 2021

drop in demand may remain permanent, for instance, areas such as transactional printing and the printing of annual reports, and manuals have been declining and the pandemic has further decreased the trend.

PM: Please share your views on the market trends and the demand drivers HP: Consumers have become used to various conveniences during the pandemic, and these will not completely go back to the old normal, such as flexible work hours, work from home, online shopping/delivery services, virtual meetings and reduced travel for work, etc. These entire set of factors have had a measurable impact on the kind of packaging needed, and how branding is to be done, and so on. Another major trend is the customers' growing demand for eco-friendliness – reusability, recyclability, conveying the sustainability of the product and the packaging – will play a huge role.

The final trend is the demand for customisation — multiple variants or even individually customised products will become greater. Subsequently, this leads to many more SKUs for the same volume which is something that the packaging companies have been witnessing already and this trend might also transform the way packaging is conceptualised.

Another major trend is the customers' growing demand for eco-friendliness – reusability, recyclability, conveying the sustainability of the product and the packaging – will play a huge role.

P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

Yash Pakka: Technology and Sustainability Go Hand in Hand With constant innovation, we have evolved into a sustainable packaging solutions provider, which caters to the food and the pharmaceutical segments, for their wrapping and packaging requirements.

Mr. Shailesh Singh, Paper Sales Head, Yash Pakka Ltd.

E

stablished in 1981, Yash Pakka Ltd. started producing low grammage kraft grades of paper.

B e g i n n i n g w i th j u s t o n e p a p e r - m a k i n g machine, they successfully doubled capacity on that machine, then added a second machine in 1991 to more than triple their paper-making capacity. This level of growth within ten years helped them quickly establish dominance over the low grammage kraft market.

Gradually, Yash Pakka got into compostable packaging and launched CHUK - a compostable packaging tableware brand made from sugarcane residue. In an interview with Paper Mart, Mr. Shailesh Singh, Paper Sales Head, Yash Pakka Ltd. talks about the company's manufacturing capabilities, product portfolio, market trends, and demand drivers.

Paper Mart: Tell us about your company and manufacturing capabilities - monthly paper converting capacity and the key technologies you have in-house.

Shailesh Singh: Yash Pakka is one of the pioneers in compostable packaging. With constant innovation, we have evolved into a sustainable packaging solutions provider, which caters to the food and the pharmaceutical segments, for their wrapping and packaging requirements.

Yash Pakka is nimble enough to provide the best products in the market. We are committed to innovating and developing sustainable packaging products at scale, integrating sustainable solutions which provide an

38 | www.papermart.in / August-September, 2021

alternate to single-use plastic. For us, technology and sustainability go hand in hand.

We use 3 MG paper manufacturing machines along with 11 130 TPD & 140 TPD for compostable tableware. The 8.5 MW power plant helps us to be 100 percent self-reliant and it is based on bio-based fuels. Nearly 95 percent of chemicals are recovered.

Furthermore, the product development and innovations are aligned to the dynamic market needs. Through our robust technological approach, we cater to a 30-80 GSM specialty paper range for food & FMCG packaging. While the moulded tableware, branded as CHUK, has a prominent presence in Indian QSRs.

PM: What challenges do you face with regard to the quality of the paper? Please share some of your key expectations from the paper mills.

SS: The shade of bagasse changes over time and most customers want consistency as a brand identity. Hence, making the customer understand such variability is a challenge for us.

Over time, as the fiber in storage ages so do its inherent properties eventually resulting in paper properties deviation. Therefore inputs need to be consistently monitored and action needs to be taken for desired outcomes.

Bagasse, which is our primary raw material, is a short fiber with limited strength. We innovate to make highstrength paper through a short fiber.

GSPBL

Gayatrishakti Paper & Boards Ltd. Kherani Paper Mills Pvt. Ltd.

Largest Manufacturers of High Strength Kraft Paper - Test Liner - White Top Liner Wide Ranges of Premium Quality of Coated Duplex Boards, Grey Back & White Back, Playing Card, & Blister Pack Board Etc

Mumbai Office: Raheja Plaza, 412, 4th Floor, Plot No. 15/B, Shah Industrial Estate, Next to AFCON, Off. Link Road, Andheri (W), Mumbai-400 053. Tel: (91-022) 4238 0000 Fax: (91-022) 4238 0011.

Vapi Factory: Gayatrishakti Paper & Boards Ltd. Plot No. 799/1, 3rd Phase G.I.D.C. Vapi - 396 195 (GUJARAT) Tel No. (0260) 2400451 / 2401588 Fax No. (0260) 2400451 / 2401588

Kherani Paper Mills Pvt. Ltd. Plot No. 799/1, 3rd Phase G.I.D.C. Vapi - 396 195 (GUJARAT) Tel No. (0260) 2400411 / 2400294 Fax No. (0260) 2400294

Gayatrishakti Paper & Boards Ltd. Unit - II Plot No. 5003/1, GIDC, Sarigam – 396155.

Tal. Umargaon, (GUJARAT) Tel No. (0260) 2400451 / 2401588 Fax No. (0260) 2400451 / 2401588

info@gspbl.com | gayatrishakti@vsnl.net | www.gspbl.com

P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

Owing to the shift in demand from offline to online shopping on the back of the COVID-19 outbreak, the market has witnessed a paradigm shift to ecommerce paper packaging.

Our key expectations from paper mills are persistent quality, sustainability in the product supply chain, timely delivery, brand visibility, and creating a trustbased relationship.

PM: With the 'New Normal' imposed due to the pandemic, what is the current market situation, and what are your projections for the future?

SS: Since the pandemic outbreak, consumer expectations have changed at an unimaginable pace. They are looking at all stakeholders, including government, fellow citizens, and brands to take positive steps towards health, safety, and sustainability. Post-COVID, there will be increased pressure on the recycling industry to enhance infrastructure to successfully separate recyclable packaging. The post-COVID-19 packaging industry looks very similar to the packaging industry today. Those suppliers who are able to provide not only sustainable

40 | www.papermart.in / August-September, 2021

raw materials but also drive sustainability through extended shelf life will be positioned for long-term growth.

PM: Please share your views on the market trends and demand drivers.

SS: Owing to the shift in demand from offline to online shopping on the back of the COVID-19 outbreak, the market has witnessed a paradigm shift to e-commerce paper packaging. That became a driving force for the paper industry to tap this market segment. Consumers prefer ordering food online and that is creating robust demand for food-grade paper & paperboard. The Government of India's recent circular to ban single-use plastics may become a driving force and an opportunity to push sustainable products to the consumer market.

The reliance on e-commerce businesses has resulted in brands opting for more cost-effective solutions in the wake of the pandemic.

The Government of India's recent circular to ban single-use plastics may become a driving force and an opportunity to push sustainable products to the consumer market.

P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

Riyo Parapack: Corrugated Packaging on the Cusp of Strong and Steady Growth The Indian corrugated market at the moment is stable and poised for a very strong growth in the next several years, particularly, with the rise in food packaging and e-commerce packaging.

Mr. Rishabh Agarwal, Director, Riyo Parapack Pvt. Ltd.

R

iyo Parapack Pvt. Ltd. is a Mumbai-based packaging company offering a wide range of corrugated packaging solutions under a number of sub-brands. The company has recently introduced a B2C-based platform offering a range of packaging solutions for small businesses & individuals. Further, the corrugated packaging provider is going to undertake a Greenfield expansion project which is scheduled to be completed at the end of 2022.

Paper Mart interviewed Mr. Rishabh Agarwal, Director, Riyo Parapack Pvt. Ltd. wherein he shares an overview of the company, their manufacturing capabilities, the key expectations from the paper mills, the current challenges facing the corrugated industry, and their plans for the future.

Paper Mart: Tell us about your company, the manufacturing capabilities, monthly paper converting capacity, and the key in-house technologies.

Rishabh Agarwal: Riyo Parapack is a family-owned enterprise established in 1996-97. We began our journey with two semi-automatic machines in Daman. This year marks the 25th anniversary of the company which is a significant milestone for us.

In 2007, we set up a fully automatic 5-ply board line purchased from JS Machines in China at our facility in Vapi, Gujarat; and we gradually discontinued our operations in Daman. In 2010, we set up a second line in the Vapi factory. For a long time, we were one of the few

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packaging companies in India to have two automatic production lines under one roof.

Our unit is equipped with enormous capabilities. We also have different types of automated converting machines. At present, we have four inline flexo printer die-cutters, and we are presently converting about 1,500 tonnes of paper per shift.

PM: What challenges do you face with regard to the quality of paper and paperboards?

RA: While there are a few good paper mills that are exceptionally sincere and diligent in their pursuit of quality, the rest of the paper mills are not qualityoriented. In fact, owing to the fragmented market situation, they have not been under any pressure to produce quality products. This has been a persistent concern in the entire value chain of the industry, starting from paper leading up to the corrugated boxes.

As it is said that “Necessity is the mother of invention”, there are competent solutions to cater to the needs of the customers looking for high- quality products.

Nevertheless, the market is so diversified that on one hand, there are customers who are looking for excellent quality, and on the other, there are customers who are fine with substandard products. This creates a huge difference.

The second major concern is that the waste management system and the recycling system are inadequate in India.

The improper collection of waste paper and the chal-

“If behind every successful man is a women, then behind every successful product is it’s packaging” w w w. s k p m il. co m

Shree Krishna Paper Mill & Industries Limited Manufacturers of: • Maplitho & Offset Printing Paper

• Insulating Kraft Paper

• High BF Kraft Paper

• Thermal Sensitive Paper

• Shuttering Base Paper

• Chromo Paper (For Gutka)

• Newsprint

• Release Paper

• Colour Printing Paper

• Grease Proof Paper/Food Grade Paper

Regd Office: 4830/24 Prahlad Street Ansari Road, Daryaganj, New Delhi-110001 Ph.: 011-46263200,3261728 & 23267253 Fax: 91-11-23266708

Contact: Mr. Man Singh Ph.: 011-46263214 Mobile : 9311182389 Email: man.singh@skpmil.com

Mr. Devkishan Chanda Ph.: 011-46263210 Mobile : 8850105601 Email: devkishan.chanda@skpmil.com

P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

‘'While there are a few good paper mills that are exceptionally sincere and diligent in their pursuit of quality, the rest of the paper mills are not quite quality-oriented.'' lenges in waste segregation have a definitive impact on the waste paper-based mills in the country. As a result, the availability of short and long fibers required for producing quality paper is a major concern for the paper industry. The Indian waste paper-based mills have to rely on imported waste paper for their raw material needs.

This practice is likely to continue as there is no choice available. Also, with the growth in the paper-based packaging industry, the demand for paper will grow and since we have a fiber shortage, we will have to continue depending upon the imports of waste paper.

Talking about the brighter side of the industry, in the last few years, several Indian paper mills have substantially upgraded their manufacturing units. Many new mills have introduced advanced technology resulting in more export opportunities. However, we still have a long way to go.

PM: What are your major expectations from the paper mills?

RA: A few years ago, the RCT test, which is an important criterion for producing a high-quality corrugated box, was conducted by just a few paper mills in our country.

However, the approach of the mills is changing for the better. Now, some of the fundamental standards like consistency, proper standardisation and other important factors like odour in the paper are being given more attention than before.

Moreover, there was no distinction made between testliner and fluting grade, which is an international norm. These are a few important factors that need to be addressed by the paper mills. However, on the positive side, there are a few paper mills which are taking initiatives and paying close attention to the above mentioned factors by working closely with the converters. These mills are bound to emerge as winners in the long run and hopefully, other mills will also take a cue from them and become more quality-oriented.

PM: With the emergence of the new normal due to the pandemic, what are the current market scenario and your projections for the future?

RA: The pandemic has not significantly impacted the

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corrugation industry from production part — apart from usual issues like lower productivity due to minimum manpower and getting spare parts from overseas. At the sametime it is facing unprecedented challenges from front of paper prices and consistent supply chain. In the long term, the Indian corrugated market is poised for strong growth in the next few years, particularly, with the rise in food packaging, e-commerce packaging, etc. Also, the world is looking at India as a very important alternate to China, coupled with the 'Make in India' program which is going to prove promising for the further growth of the corrugated industry.

The raw material availability is going to be a challenge owing to the high dependence on imports for waste paper. This creates a strong need to improve the recycling and waste collection methods in addition to securing the fiber availability from overseas.

The third important factor is adequate skill development for the corrugated industry. Around fifteen years ago, the corrugated packaging was under SSI (small-scale industry), which meant that it could not have large investments. Infact, during that time, Sri Lanka had more automated corrugated plants than India, which has now changed. In the past few years, large investments have been in automation and now, the corrugated box factories have become bigger in scale than earlier.

The Indian government has managed the COVID situation extremely well and a lot of groundwork has been done for any such situation that might arise in the future. Overall, the government has done a superb job in managing the crisis.

In the medium term, the corrugated industry could have a set of challenges pertaining to worldwide disruptions which will have a ripple effect in our journey back to normalcy.

It seems that the turbulent times will continue as we are seeing that every other day, there is some news of another matter affecting the whole society at large. For instance, in the last few days, the situation of Evergrande Group's crisis in China and Coal/Power Crisis, these are the issues that might create spillover effect on the global economy as well.

Corrugated Box users must have to understand that they need to support our industry to help them. In the present scenario the corrugated industry is passing through a crisis due to paper & supply chain disruptions. It is important for them to understand that we have always delivered but times have changed. A healthy corrugated box industry is essential to them.

PM: Do you have any particular expectations from the future generation – the youth looking to make their career in the packaging industry?

P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

‘'The corrugated packaging industry is going to attain strong demand and growth of around 10 percent yearover-year for the next five years.''

RA: With the huge growth taking place in the packaging industry, we have seen that there has been a rise in the number of people who are looking to make their career in the packaging industry. A few days ago, the government has proposed to declare the Indian Institute of Packaging an institution of national importance in the draft bill. It will enable the institute to develop and conduct courses in an autonomous way for graduate and post-graduate degrees, and postdoctoral courses, and undertake research on international marketing in packaging. This marks a very significant move for the Indian packaging industry. It will open up avenues for more research on product packaging which will lead to the advancement of the packaging industry.

The major concern is that the students should be trained and equipped with the required skills for the factory job.

There should be a greater emphasis on the skill development of the young generation and familiarising them with the advanced techniques in the field of packaging that will enable them to become a part of a competent and skilled workforce.

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PM: Kindly share your views on the market trends and the demand drivers.

RA: The corrugated packaging industry is going to attain strong demand and growth of around 10 percent year-over-year for the next five years. The major demand in the industry has been driven by the surge in e-commerce, food industry which includes packaged food as well as the packaging for fruits and vegetables.

The large multinational companies sourcing in India for the Indian market and the exports as I already said that they would be looking at India as a strong alternative to China.

PM: Please talk about the recent developments, product launches, and expansion plans for the future.

RA: Shedding some light on the recent past, with the outbreak of the pandemic, the first wave of the pandemic did not affect our business operations substantially.

However, in the second wave of the pandemic, we did face a few challenges to the degree that we had to press the “reset” button as we had to reorganize, reassess and restrategise our business plans.

With regard to our new developments, we launched Let's Pac in 2021 — which is an online platform principally with a unique, first-of-its-kind B2C model for corrugated box users in India. The platform is essentially aimed towards providing solutions for packaging requirements in small businesses and households. For instance, we have packaging solutions for a business that needs to courier a few samples of their products such as

P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

‘'We launched Let's Pac in 2021 — which is an online platform principally with a unique, first-of-its-kind B2C model for corrugated box users in India.''

garments, shoes, etc. Also, if one wants to store documents in a proper way, we provide different kinds of parcel boxes and storage boxes under our sub-brands Postobox and Durobox respectively.

During the lockdown period, we witnessed a rise in the number of small businesses selling home-made food.

We have the ideal packaging solutions for their requirements such as Freshobox which is specifically made for pizza or cake delivery.

With regard to expansion plans — we have planned a

new Greenfield project, and already have land adjoining our factory for the same. We will be incorporating a new generation state-of-the-art corrugation line. With this investment, we are planning a capacity to convert around 8,000 tonnes per month. The new Greenfield project is slated to start at the end of the year 2022. At present, we are at the planning stage of the proposed expansion.

Presently, we are focusing on research and development, on maintaining consistency in quality and planning for new product development in the future. At the same time, we are aspiring to be a 100 percent renewable energy-based company.

PM: Would you like to add anything else to this conversation?

RA: The corrugated industry seeks to attain superior quality products from its suppliers in a consistent manner. I would like to sum up our interaction by saying that the Indian corrugated packaging industry is poised for good growth.

Further, the level of quality in the domestic industry is rising to be at par with the global-level and the automation in corrugated plants is also steadily increasing.

Saica Announces Investment of USD 800 Million to N•E•W•S Accelerate US Growth Plans Saica is currently building its first production site in the US: the corrugated plant in Hamilton, Ohio, is scheduled to open in early 2022.

September 10, 2021

S

pain's paper and packaging group Saica is set for further growth on the US market. The company has announced that it would invest USD 800 million over the next five years to expand its presence in the United States. The money would be spent on "strategic acquisitions or new plant construction", according to the company.

Specific growth plans under the USD 800 million investment are still being determined. Saica's investment could bring approximately 500 jobs to the market. n

Saica Pack

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P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

Evolution of Paper-Based Packaging The use of paper for packaging, products like cardboard, paperboard, shipping sacks, and paper bags, began as early as 1817. The types of paper-based packaging, as we know today, have been through a number of huge transformations. Let's have a look at the origins of paper-based packaging through the timeline.

1890: Changed the Course of History The first commercial cardboard box was produced in England in 1817.

The year 1890 was truly the year of historical significance when we talk about the history of paper-based packaging.

1800

1817: Where it all began

1844 & 1855: Paper Bags

In the 1870s, glued paper sacks and the gusset design were conceptualised which paved the way for producing paper bags as we know today.

1850s: Rise of Corrugated Paper The history of corrugated paper dates back to 1850 when the first machine to manufacture multi-layer cardboard was invented. In New York, the first patent for corrugated paper for packaging was filed in the year 1871.

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25 18

Initially, the commercial use of paper bags began in the year 1844. In 1852, the paper bag-making machine was invented in the United States.

In that year, a Brooklyn-based printer and paper bag manufacturer Robert Gair, by sheer chance, invented the precut box when he was printing paper bags and a metal ruler malfunctioned –ending up in cutting through the bags. That being so, he suddenly realised that precut paperboard boxes could be produced by cutting and creasing paperboard. It was closely followed by when he implemented this idea to corrugated cardboards.

18 50

1875

P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L 2020s: Rise of Smart Packaging With the inclusion of NFC chips, QR codes and temperature sensors and augmented reality, smart packaging will be at the forefront of packaging industry changes in 2020 and beyond.

20 2 5

2010: LCA Test

0 0 20

Corrugated Packaging Alliance introduced, for the first time, the Life Cycle Assessment (LCA) tests for corrugated boards.

1990s: Recycling Impact

1975

1909: Defining Standards In 1909, several fiberboard manufacturers came together to form an association – The Fibre Shipping Container Association, to clearly define the quality standards for corrugated boards primarily based on the thickness of facings and bursting strength, measured by the Mullen tester.

The upsurge in recycling in the 1990s further transformed the industry. More Old Corrugated Containers (OCCs) were getting recycled to reclaim the fibers. While the fiberboard content varies depending on recycling, it is still relatively higher in kraft-based content.

Also, Fibre Box Association introduced a modular standard known as the Corrugated Common Footprint.

5 2 19 1900

19 50

1906: Cereal Packaging The Kellogg brothers, famously known for coming up with Corn Flake cereal, began using cardboard to distribute and market their cereal products a s e a r l y a s 19 0 6 . I t w a s packaged in 100 percent paperboard packaging.

1950: Corrugated Containers Division In the middle of the 20th century, TAPPI (Technical Association of the Pulp and Paper Industry) developed the Corrugated Containers Division that is responsible for developing most of the material test methods used today.

1940s: Advent of Water-Resistant Corrugated Boards After the Word War II, the paperboard mills couldn't keep its pace with the ever-increasing demand for water-resistant fiberboards.

Subsequently, at the time, the kraft board mills and box makers came up with a new type of corrugated paper board with heavy liners and water-resistant glue.

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P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

York Print & Pack: Trend of Innovative Cartons Boosting Demand for Value Addition on Packaging Our extensive in-house infrastructure enables us to handle all kinds of print production including prepress and post-production processes on an end-to-end basis.

Mr. Gautam Tandon, Director, York Print & Pack Pvt. Ltd.

Y

ork Print & Pack Pvt. Ltd. is a sister concern of York Print Pvt. Ltd. (YPPL) - one of the leading manufacturers and suppliers of printed folded cartons and corrugated boxes in India with its clientele across Asia. Embarked on the path to deliver the best and most innovative packaging experience to its clients, YPPL stands at the zenith of perfection in the packaging industry since its foundation three decades back. In a conversation with Paper Mart, Mr. Gautam Tandon, Director of York Print & Pack Pvt. Ltd. presents an overview of the company along with the market trends.

Paper Mart: Tell us about your company and manufacturing capabilities — monthly paper converting capacity and the key technologies you have in-house.

In spite of our dependence on large mills for quality products, we face frequent problems due to deviations in quality parameters as well as overall usability.

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Gautam Tandon: With a marked presence in the field of printing and packaging over three decades, York Print & Pack is indeed a force to reckon in the eastern part of India. York Print & Pack is one of the largest and most technologically advanced print packaging facilities in the eastern part of the country. We are a world-class completely integrated organisation driven by ongoing technology initiatives, stringent security & quality control measures, high-level service commitment and most importantly cost-effective approach towards service delivery in time. Our extensive in-house infrastructure enables us to handle all kinds of print production including pre-press and post-production processes on an end-to-end basis. We convert approx. 700 tonnes of paper/board per month.

P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

With e-commerce taking up a huge share of market sales, packaging requirements for the same is on a rise.

PM: According to you, what would be the criteria for future packaging requirements? What challenges do you face with regard to the quality of paper & paperboard?

GT: In spite of our dependence on large mills for quality products, we face frequent problems due to deviations in quality parameters as well as overall usability. Deviations in respect of GSM and size are absolutely non-acceptable from the bigger mills that have modern machinery/equipment to control. Even in high-value items, we face uneven coatings, hickies and dust, crease, etc. Apart from deviations in quality parameters we also face shade variations and board waviness.

The quality defects mostly originating at the production stage in the mills put us into great difficulty to supply converted quality products to our customers in time. Mills should take care to overcome these shortcomings.

PM: With the 'New Normal' imposed due to the

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pandemic, what is the current market situation and what are your projections for the future?

GT: After the New Normal, the future of the packaging industry seems to be bright. Consumers have become more conscious as far as the quality of the packaging is concerned. With e-commerce taking up a huge share of market sales, packaging requirements, for the same, are on a rise.

PM: Please share your views on the market trends and the demand drivers.

GT: The trend being shifted from regular to innovative cartons has resulted in rising demand for value addition on the packaging. Given the prevailing trend, the customer is ready to pay for good quality and innovative packaging.

KROFTA ENGINEERING LIMITED NEW Triple Wire Belt Filter Press (Gravity Table + Belt Filter Press)

Krofta introduces newer enhanced capacity Belt Filter Press.

A new innovative unique technique, which will improve overall efficiency for sludge dewatering SALIENT BENEFITS: Ÿ First in the Country : Launched by Krofta : Triple Wire Belt Filter Press (Gravity Table + Belt Filter Press) Ÿ To enable handling of Higher throughput Ÿ Ability to handle Higher Solids per day Ÿ More Space for Squeezing the sludge in wet zone Ÿ Evenly spread of Sludge helps in more dewatering & better drainage Ÿ Compact structure and modular design Ÿ Flocculator as inbuilt supply for better dewatering MODELS AND TECHNICAL DATA TYPE Length, mm Width, mm Height, mm Belt Area, m2 Belt Speed, m/min 3 Wash Water, m /hr.

Air Consumption, m3/hr.

Motor Power, kW

BFP 1.1 T 3500 1430 2200 21.5 2 – 10 8.5 1 0.75 + 0.55

BFP 1.6 T 3500 1930 2200 31.5 2 – 10 13 1 1.1 + 0.75

BFP 2.1 T 3500 2430 2200 41.0 2 – 10 16 1 1.1 + 1.1

BFP 2.6 T 3500 2930 2200 50.7 2 – 10 21 1 1.1 + 1.5

Krofta Engineering Limited Durga Bhawan, A-68, FIEE Complex, Okhla Industrial Area Phase-II, New Delhi – 110020.

EPBX : +91-11-4724 2500 | E-mail: krofta@kroftaengineering.com | Web : www.kroftaengineering.com

P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

Packman Packaging: Paper-Based Packaging to Witness a Strong Growth Momentum Packman manufactures 1 lakh corrugated boxes everyday in addition to other packaging products… In terms of technology, our focus is on incorporating smart packaging in the paper-based packaging range.

Mr. Gaurav Jalan, Founder and Director, Packman Packaging Pvt. Ltd.

S

tarted in 2002, Packman Packaging manufactures a range of eco-friendly paper-based corrugated boxes. The Indian packaging company supplies to leading multinational companies of the likes of Amazon India, Flipkart, Samsung, Bosch, and others with their sustainable packaging products. In its factory in Greater Noida, Packman Packaging manufactures paper-based corrugated boxes in various shapes and sizes.

In an exclusive interview with Paper Mart, Mr. Gaurav Jalan, Founder and Director, Packman Packaging Pvt. Ltd., speaks about the innovative capabilities and disruptive technologies being used at the company, the key expectations from the Indian paper mills and the demand drivers of the packaging industry.

Paper Mart: Tell us about your company and manufacturing capabilities — monthly paper converting capacity and the key in-house technologies of Packman Packaging.

Gaurav Jalan: Packman Packaging is one of India's top manufacturers of corrugated boxes, corrugated rolls, bubble rolls, bubble pouches, courier bags, POD jackets, duct tapes, e-commerce shipping bags and many more.

Spread over thousands of square meters of area, Packman's state-of-the-art manufacturing unit which is based in the Delhi-NCR region, has some of the world's finest packaging material manufacturing machinery.

With the world's best printing technology, it is well

54 | www.papermart.in / August-September, 2021

ensured that our customers and clients get fast and efficient delivery and high-quality brand representation through the product packaging. Furthermore, most essentially, the companies face the least or zero goods damage while transporting and storing the products.

Packman manufactures 1 lakh corrugated boxes everyday in addition to other packaging products. As a matter of fact, the corrugated boxes are Packman's best and one of the most saleable products. In terms of technology, our focus is on incorporating smart packaging in the paper-based packaging range. Paper-based packaging is extensively worked upon as they could be recycled and reprocessed in the future.

PM: What challenges do you face with regard to the quality of paper and paperboards? Please share some of your key expectations from the paper mills.

GJ: The challenges with regard to the quality of paper and paperboards have increased manifold owing to the fact that since last year onwards, there has been a significant shortage of raw materials along with the sharp increase in prices. It has majorly affected the packaging industry and the production of both paper and paperboards which are the prerequisites for the packaging manufacturers.

Some of the major problems confronting India's pulp and paper industry are high cost of production caused by insufficient availability and high cost of raw materials, power expense, and concentration of mills in one specific

P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

The challenges with regard to the quality of paper and paperboards have increased manifold owing to the fact… there has been a significant shortage of raw materials along with the sharp increase in prices. It has majorly affected the packaging industry. area, in addition to the non-availability of good-quality fiber, uneconomical plant size, and outdated technologies.

The packaging manufacturers expect the paper prices to reduce since it severely affects manufacturing and increased costs also means lesser sales in certain segments of the industry. Consequently, the paper manufacturers should consider these factors for the long-term prospects.

PM: With the new normal imposed due to the pandemic, what is the current market situation and what are your projections for the future?

GJ: Certainly, every industry has been hit due to the pandemic. And packaging is no different either. Though one good thing which happened during last year's first wave of the pandemic is that several people preferred to buy products online instead of conventional shopping.

The surge in e-commerce sales also helped in boosting the growth of the packaging industry to a great extent because of the ensuing higher demand for packaging boxes and other materials. However, this is just one aspect.

The rise in the cost of raw materials impacted production as well. Lesser manpower also meant lesser production numbers and subsequently, it was reflected in the declining sales with steep prices. These changes have now been gradually accepted. Though the markets are slowly opening, it is going to take a lot of time to fully recover. We hope to see the revival in the coming times as the future trend is going to be such that people will continue to prefer

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buying products online. This could be a favourable opportunity for the packaging industry to work upon further. Also, while the food industry currently holds the largest share in using packaging products, the higher demand of the packaged food products certainly augurs well for the overall packaging industry.

PM: Please share your views on the market trends and the demand drivers.

GJ: As stated above, the demand for paper-based packaging will continue to grow as the trends indicate a new buying pattern among the masses and businesses as well. With the growth in the FMCG and the pharmaceutical industry, the packaging manufacturers will be subsequently benefited.

Thus, with time, the market situation is projected to witness an upward curve. In addition, the demand for ecofriendly packaging products is increasing as a result of which the packaging industry has already started focusing on these aspects. Biodegradable bags and spill-proof packages will be in trend in the coming years.

The surge in the e-commerce sales also helped in boosting the growth of the packaging industry to a great extent because of the ensuing higher demand for packaging boxes.

P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

Excel Cartons: Paper Well-Accepted by E-Commerce Industry as a Replacement to the Flyer Bags

(L-R) Mr. Manish Bansal and Mr. Ritesh Jain, Directors at Excel Cartons Pvt. Ltd

We are among very few corrugators in the country who will be getting the FSC certification for sustainable packaging by the end of Oct-2021.

N

agpur Carbon Pvt. Ltd. was established in 1991.

The group gradually expanded its footprint by opening Nagpur Packaging Pvt. Ltd. and Excel Cartons Pvt. Ltd. The companies are situated at three different locations of Nagpur on a sprawling 6.5 acres and have a conversion capacity of around 1500 tonnes of paper per month in total. In an interaction with Paper Mart, Mr. Manish Bansal and Mr. Ritesh Jain, Directors at Excel Cartons Pvt. Ltd. talks about the company's

58 | www.papermart.in / August-September, 2021

manufacturing capabilities, challenges with regard to the quality of paper, current market situation, and future trends.

Paper Mart: Tell us about your company and manufacturing capabilities — monthly paper converting capacity and the key technologies you have in-house.

Manish Bansal: We introduce ourselves as the leading supplier of corrugated boxes in Central India. We started our operations in 1991 under the name of M/s Nagpur Carbon Pvt. Ltd. with an installed capacity of 250 tonnes per month. After 10 years, we expanded by opening another box unit M/s Nagpur Packaging Pvt. Ltd. taking the installed capacity to 500 tonnes per month.

In the year 2014, Excel Carton Pvt. Ltd. — a fully automatic corrugation plant was started by me with Mr. Ritesh Jain, who is also a second-generation entrepre-

P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

We are proudly associated with Haldiram's, TATA Companies, Herbalife, Future Retail, Spacewood Furnitures, ABIS group, Briskfarm, Seagrams, Plasto, Flipkart, CIAN Agro, HNI (India) among others. neur managing a similar line of manufacturing corrugated boxes by brand Industrial Packaging Products successfully. Excel Cartons Pvt. Ltd. is the only company with a unique facility of having a combination of fluting namely Narrow/C/Broad/E flutes in a single line. It has an installed capacity of 1500 tonnes per month. Our brand — Industrial Packaging Products is a fully automatic plant having an installed capacity of 1500 tonnes per month located within the city limits on a sprawling area of 90,000 sq. ft.

We have a Komori Lithron (Japan) multi-color offset printing machine which offers a range of colourful boxes to our customers. Our multi-colour division is handled by one of the best printing techies of the town. We have an in-house honeycomb expander and lamination facility, and are the only one in Central India providing packaging solutions using paper honeycomb material.

All our companies are situated at four different locations of Nagpur on sprawling 6.5 acres land with a covered area of 80,000 sq. ft. The four companies, put together, have a conversion capacity of average 3500 tonnes per month with an approximate gross annual turnover of INR 100 crores.

As an expansion plan, we are coming up with one of the largest automatic corrugation plants in Central India with a capacity of 2500 tonnes per month which will be installed by January 2022 on a different location making it our 5th facility of production. This added facility will take our total capacity to 6000 tonnes per month. The running speed of the machine will be 200 meters per minute (fastest in Central India). Our new facility includes Donguang make 4 colour printer slotter rotary die cutter, high-speed auto gluing and stitching machine (this machine can glue 1 lakh boxes per day).

Currently, we are proudly associated with Haldiram's, TATA Companies, Herbalife, Future Retail, Spacewood Furnitures, ABIS group, Briskfarm, Seagrams, Plasto, Flipkart, CIAN Agro, HNI (India), among others.

We have our own fleet of 20 trucks including 8 containers to supply boxes pan India. We are supplying boxes starting from western regions like Mumbai, Pune,

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Ahmedabad, Nashik to eastern regions like Kolkata, Jamshedpur, and Odisha; and from southern regions such as Vizag, Vijayawada, Hyderabad to northern regions Bhopal, Indore and Haryana.

We are among very few corrugators in the country who will be getting the FSC certification for sustainable packaging by the end of October 2021.

PM: What challenges do you face with regard to the quality of paper & paperboard? Please share some of your key expectations from the paper mills?

MB: Paper mills have improved the quality of paper and consistency in the supply of paper exponentially.

Moisture content issue in the kraft paper is a major concern that needs to be sorted out by the mills. Erratic price fluctuations done by paper mills are a serious matter of concern for the corrugators. Since we are moving to very high-speed machines with a speed of 200 meters, we expect upgradations in rewinding and run ability of the reels from the paper mills.

PM: With the 'New Normal' imposed due to the pandemic, what is the current market situation and what are your projections for the future?

MB: The worldwide lockdown to curb the COVID-19 pandemic has impacted each person mentally, physically, and financially. Many people have lost their jobs, and through the e-commerce concept, the new opportunity for small businesses like the supply of essential commodities, home delivery of food that requires boxes has helped us to remain in the business in this tough situation. Now, we are approaching normalcy and the festive season is around the corner where all the businesses will start their operation soon which will help us to increase our business. We are seeing approximately 40 percent growth in the current year.

PM: Please share your views on the market trends and the demand drivers.

Ritesh Jain: The government has now imposed the ban on single-use plastic hence paper packaging is the best

P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

The boom in e-commerce start-ups, especially in the food industry, has increased the demand for paper products and we are sure it will improve multi-fold in near future. environment-friendly alternative. Also, the boom in ecommerce start-ups, especially in the food industry, has

increased the demand for paper products and we are sure it will improve multi-fold in near future. Paper has been well accepted by the e-commerce industry as a replacement for the flyer bags and bubble packaging. The fruits and vegetables have started consuming corrugated boxes in large quantities. Top e-commerce players like Amazon, Flipkart, Myntra, Nykaa are shifting to paper packaging which in turn has increased the demand for kraft paper. This is the first time that Indian paper is getting exported in many countries; hence, there will be more demand for paper in near future, which is a proud thing for all of us.

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P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

Mayura Offset: New Horizons in Retail, Food Packaging to Boost Demand of PaperBased Packaging Products In the last 10 years, the Indian paper industry has upgraded a lot in terms of quality and consistency, the only key area now, where the paper mills need to focus on is the service & distribution part.

Mr. Piyush Sinha, Managing Director, Mayura Offset

M

ayura Offset is one of the leading and innovative manufacturers of cartons, inserts & outserts for the pharmaceutical industry.

Established in the year 1987, Mayura has evolved from a small letterpress to a packaging firm with imported machinery manufacturing top-rated products for pharmaceutical companies. Paper Mart interviewed Mr. Piyush Sinha, Managing Director at Mayura Offset, wherein he shares his views on the key technologies of his company along with the current market situation, market trends, and projections for the future.

Paper Mart: Tell us about your company and manufacturing capabilities — monthly paper converting capacity and the key technologies you have in-house.

Piyush Sinha: We have an installed capacity of converting around 500 MT/month of paperboard in the form of cartons, labels & leaflets. Also, we have recently started our flexo division for catering to the requirements of roll form labels. We have in-house facilities for pre-press, UV, water base, metpet, Braille embossing, specialised outsert folding system for pharma, foiling, etc.

PM: What challenges do you face with regard to the quality of paper & paperboard? Please share some of your key expectations from the paper mills.

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PS: In the last 10 years, the Indian paper industry has upgraded a lot in terms of quality and consistency, the only key area now where the paper mills need to focus on is the service & distribution part. Just-in-time delivery is the need of the hour.

PM: With the 'New Normal' imposed due to the pandemic, what is the current market situation and what are your projections for the future?

PS: Currently, there is a major gap in demand and supply in the paper category due to multiple hurdles arising due

There is a major gap in demand and supply in the paper category due to multiple hurdles arising due to lockdowns, pricing of basic pulp, unavailability of raw materials and other related items, but if we look from a broader angle, Indian paper industry has the opportunity to become a new global supplier for paper in coming near future.

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P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L to lockdowns, pricing of basic pulp, unavailability of raw materials and other related items. But if we look from a broader angle, the Indian paper industry has the opportunity to become a new global supplier for paper in the coming future as the demands of Indian paper & paper-based products have grown tremendously in the last few months. Demand in the food packaging sector is also growing very fast due to the majority of orders being converted into take-home delivery. With paper being the

Demand in the food packaging sector is growing very fast due to the majority of orders being converted into take-home delivery.

most easily recyclable eco-friendly substance, new horizons in retail food packaging are coming which will give a further boost to the demand for paper-based packaging products.

PM: Please share your views on the market trends and the demand drivers.

PS: Apart from pharma & food packaging buyers, there is not much change in the buying pattern of the buyers.

Previously, pharma's entire supply planning was based on projections but today they are even working on a make-to-order concept due to the unstable cost of raw materials and packing materials.

BillerudKorsnäs Relaunches Coated White-Top Kraftliner for Litho-Laminated Packaging

N•E•W•S

Pure Supreme is a well-established premium white-top kraftliner, optimized for offset printing.

October 20, 2021

B

illerudKorsnäs has launched an upgraded version of Pure Supreme, which is more than a facelift – it could even be regarded as a new product. It offers excellent print results in terms of colour fidelity and lifelike image reproduction. Its strength and stiffness ensure high runnability, allowing for high-speed printing and converting processes.

New Pure Supreme is the latest in a series of new products to come out of BillerudKorsnäs' KM7, the world's most modern board machine. The advanced technologies applied in KM7 have made it possible to combine several valuable product properties: printability, strength, stiffness, appearance, consistency, and purity. Like all BillerudKorsnäs products, Pure Supreme is made of 100% pure and strong primary wood fibers, sourced from responsibly managed forests. With the high capacity of KM7 – 550,000 tonnes/year – global availability is high.

For premium brands with a need for appealing, highperformance packaging, Pure Supreme is a perfect choice – and the advantages are easily explained. The smooth and fully coated surface gives the liner an attractive appearance, exceptional print results, and opportunities for interesting varnishes and foils. Primary wood fibers in a 3-ply structure make Pure Supreme strong and minimize the risk of

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Pure Supreme

washboarding. A mid-layer of CTMP and kraft pulp provides bulk, stiffness, and stability to ensure high runnability.

“The combination of strength and appearance is unique in this product. Normally, a customer has to choose one or the other product property. But with Pure Supreme we can offer both,” says Rolf Gustafsson, Senior Director Product Management Containerboard at BillerudKorsnäs. “And thanks to its strength, Pure Supreme enables great light weighting possibilities; less packaging weight saves cost and reduces the environmental footprint.” n

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P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

KIG Kraft: Kraft Paper to Gain Momentum amid Plastic Ban KIG is planning to set up an automatic corrugation plant in the coming years which would increase the production level by four times.

Mr. Hemant Saraogi, Director, KIG Kraft Tech Containers Pvt. Ltd.

K

IG Kraft Tech Containers Pvt. Ltd. is one of the fastest-growing corrugated box manufacturers.

The company has been in the corrugated box industry for 40 years providing efficient services to a variety of industries. With the ideal combination of machines and a well-equipped lab, it claims to have a state-of-the-art unit providing successful services to its customers. In an interaction with Paper Mart, Mr. Hemant Saraogi, Director, KIG Kraft Tech Containers Pvt. Ltd. talks about the company's manufacturing capabilities, future plans, and market trends.

Paper Mart: Tell us about your company and manufacturing capabilities — monthly paper converting capacity and the key technologies you have in-house.

Hemant Saraogi: KIG Kraft Tech Containers Pvt. Ltd. is one of the fastest-growing names in the Kolkata corrugated box manufacturing industry. With over 35 years of experience in the industry, KIG has catered to a vast range of industries including paint and chemicals manufacturers, FMCG, tea exporters, solar panel manufacturers, metallurgy, safety equipment manufacturers, dry flower exporters, etc. Currently, the company is converting 200 tonnes of kraft paper every month on average.

KIG specialises in manufacturing all kinds of corrugated paperboard and products including regular slotted cartons, half slotted containers, full overlap slotted containers, lock bottom boxes, etc. With our experience, we not only make boxes of desired specifications but also

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do value engineering to optimise the cost of the package considering the product, transportation, and effective storage.

PM: What challenges do you face with regard to the quality of paper & paperboard? Please share some of your key expectations from the paper mills?

HS: There is a lack of consistency in the quality of the kraft paper either in terms of BF or RCT; there's always a deviation from the expected quality. Also, the lead time of the materials has been very erratic lately. A basic consistency is expected from the paper mills in terms of quality as well as supply of the kraft paper.

PM: With the 'New Normal' imposed due to the pandemic, what is the current market situation and what are your projections for the future?

HS: Due to the pandemic, the supply of kraft paper was majorly affected as the availability of waste paper was an issue that also led to an exponential rise in the prices of the same. In the 'New Normal', a uniformity/reduction in the price of kraft paper is expected and supply should also improve.

A basic consistency is expected from the paper mills in terms of quality as well as supply of the kraft paper.

P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L PM: Please share your views on the market trends and the demand drivers. Any new development or expansion plans you would like to share about KIG Kraft?

HS: With the issue of climate change in motion and the awareness of the plastic ban being imposed in many parts of the world, the kraft paper market is expected to boom.

Currently, KIG has a semi-automatic setup and is planning to set up an automatic corrugation plant in the coming years.

Thereby, we are planning to increase the production level by four times from the current level.

Due to the pandemic, the supply of kraft paper was majorly affected as the availability of waste paper was an issue that also led to an exponential rise in the prices of the same.

Turkey-based Kipas Kagıt Orders Containerboard Making Line from Valmet

N•E•W•S

The order is included in Valmet's orders received of the third quarter 2021. The value of the order will not be disclosed. The total value of an order of this type and delivery scope is typically around EUR 90-110 million.

Containerboard Making Line

September 17, 2021

V

almet will supply a new container board making line with extensive packages of automation and services to Batı Kipas Kagıt Sanayi İsletmeleri in Söke, Turkey. The new board making line (PM 3) will produce high-quality fluting and liner grades. The start-up of PM 3 is scheduled for the third quarter of 2023.

Valmet's delivery for PM 3 will include a high-speed container board making line from broke collection and an approach system to a reel and a winder. An OptiFlo Layering Gap headbox with new innovative aqua layering technology will be used to produce a two-layer sheet with a very good layer coverage using only one headbox and one OptiFormer Gap forming unit with shoe and blade technology. These will be followed by an OptiPress Linear press section and OptiRun Single dyer section topped with an OptiDry Twin impingement drying unit providing superior drying efficiency, excellent runnability, enhanced draw control and increased bulk, and an OptiSizer Hard sizer giving higher strength values.

The end of the machine line will be equipped with an OptiReel Linear reel combined with transfer rails, and a high-capacity

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OptiWin Pro two-drum proactive winder with Dual Unwind for even higher winding capacity. A wide scope of board machine and machine hall process ventilation systems, continuous surface size preparation and OptiSizer supply systems will be included, too.

The delivery will include Valmet DNA Automation System including process controls, drive controls, and condition monitoring, and Valmet IQ Quality Control System (QCS) with web monitoring and web inspection systems. The start-up and the further optimization of the new board machine will be supported remotely from Valmet Performance Center utilizing the latest Industrial Internet solutions. Cost Monitoring will offer real time cost information of energy consumption in the production process. The delivery will also include Valmet Paper Machine Clothing, spare parts and consumables packages.

The 9,100-mm-wide (wire) board machine will produce recycled fluting, testliner and kraft top testliner grades with a basis weight range of 60-110 g/m2. The design speed of the machine will be 1,800 m/min and the annual capacity approximately 650,000 tonnes. n

P•A•C•K•A•G•I•N•G S•P•O•T•L•I•G•H•T

ercent P 0 0 1 s e v ie h c Myntra A elivery D g in g a k c a P e Plastic-fre

dia's biggest te, Myntra, In as w tic as pl reduce rporated In an effort to giant had inco ce er m m co its estyle estival. Taking fashion and lif Big Fashion Fe its r fo s g ha in a ag tr ck e, Myn plastic-free pa a notch abov y lit bi na g. ai in st ag to su plastic in pack commitment ent single -use rc pe ign its al 0 0 to 1 s rt ny's effo eliminated pa m co e th ith is in sync w The measure packaging. to adopt green rs ne rt pa d bran opted many yntra has ad M y, ne ur jo the way, bility itiatives along In its sustaina in d an es tic siness prac its packaging sustainable bu ent plastic from rc pe 0 10 g in inat a part of this and now elim mplished. As co ac e on st ile or m r orders in is another maj d receiving thei te ar st ve ha s wraps, stomer try. All bubble initiative, the cu un co e th ss ro ith ckaging ac en replaced w sustainable pa covers have be ly po r d pe an pa s, , pe erials plastic cello ta shredded mat y dl en ri -f o d ec sustainable an s respectively. r covers & boxe pe pa tapes, and

Elopak Launches Aseptic Carton – Pure-Pak eSense Elopak has introduced an environmentally-friendly asepti c carton – the Pure-Pak® eSense. The aseptic carton has be en ma nu fac tur ed wi th the tec hn olo gy fro m El op ak 's fre sh po r tfo lio im ply ing th e ca r ton is designed to preserve the produc t integrity, safety, and the lifespan of the contents inside the pack. This has been made achievab le without the use of an aluminium layer that is generally used in asepti c packaging.

The Pure-Pak® eSen se carton has been created in tandem with Elopak's goals to co ntribute to a net-zero circular econ omy.

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Recyclable Paperb oa Lid Developed by T rd he Paper Lid Compan y and Metsä Board The Pap er L id Company a nd Metsä Board ha ve co lla bo ra te d to d e v e l o p a pa pe rb oa rd lid for takeawa beverage cups. y The lid is made fro m a dispersion barrier board, wh ich is “fully recy clable”. Making use of The Pape r Lid Company's new technology the paperboard , can be formed into the desired shape for custom ers. Both the co mpanies assert that the carbon footprint of the pa perboard lid is approximately 50 percent lowe r than that of a plastic lid.

Lactips Launches Plastic Free Paper

Lactips , sp ecialised in producing a 10 0 p e r c e n t bio-sourced casein-based pla sti c ma ter ial that is biodegradati ng a fir st- generat ion co able, has develop ed of ies the barrier propert solution that respects s ha y . The French compan cellu lose packaging op nization CITEO to devel worked with the eco-orga res su en t tha ating solution this cellulose matrix co . papers and cardboards the total recyclability of able, urced, home compost It is 100 percent bio -so and , fat , provides the oxygen and heat-sealed, and d foo ential for preser ving mineral oil barriers ess foo d g co mp lia nc e wi th pr od uc ts an d en su rin contact standards.

P•A•C•K•A•G•I•N•G S•P•O•T•L•I•G•H•T

McDonald's Almost Entire Paper Packaging from Sustainable Fiber

of DS Smith to Explore Use iber Seaweed as Alternative F ng kagi Source for Paper and Pac

McDonald's Corporat ion is on its way to achie ving its goal of sourcing all of its paper-based foo d packaging in its restau rants from the recycled or sustainable fiber. In view of its environme ntal practices, McDonald' s has placed a larger go al for its entire custome r packaging created fro m renewable, recycled, or certified sources by the year 2025. At present, 80 percent of its pack aging comes from such sou rces.

Besides, the fast-food chain is also using pa per s t r aw s a n d w o o d e n cu t l e r y i n m u l t i p le regions/countries and is exploring the use of fib er lids and reusable cups.

Coca-Cola HBC Introduces PaperBased Carton Solution to Larger Multipacks

In par tnersh ip with Graphic Pac kag ing International, CocaCol a HB C's larg er multipacks are now ava ilab le in a new fully enclosed paperbased car ton, which replaces previouslyused shrink-wrap.

HBC's larger multipacks Both KeelClip and Coca-Cola developed by Graphic packaging types are designed and in total, transitioning to Packaging; which predicts that, tions will eliminate 500 these new secondary packaging solu shrink-wrap plastic. tonnes annually of hard-to-recycle

hieving its ion is on its way to ac McDonald's Corporat ckaging in pa its paper-based food goal of sourcing all of fiber. In recycled or sustainable its restaurants from the nald's has ntal practices, McDo view of its environme r packaging for its entire custome placed a larger goal d sources by le, recycled, or certifie created from renewab packaging sent, 80 percent of its the year 2025. At pre s. comes from such source straws and ain is also using paper Besides, the fast-food ch ies and is ltiple regions/countr wooden cutlery in mu er lids and reusable cups. exploring the use of fib

Pladis Boosts Sustainability through Sonoco's Fully Recyclable Envirocan Pladis, the glo bal sna ck company of the UK's most iconic and renowned sna ck bra nds , h a s b e e n making efforts to substantially reduce its environmental impact by updating the packaging of various products to more eco -friendly alternatives.

This move is a par t of the compan y's sustainability agenda, which reflects its commitment to making all its packaging rec yclable, reusab le, or compos tab le by 2025. Most recently, pladis has made steps forward to move toward more pap er-b ase d solution s – its Min i Che dda rs and Che eselets ranges now use Son oco 's Env iroC an with paperboard end. Cracker Crisps and Mini Twiglets are also set to use EnviroCan later this year.

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P•A•C•K•A•G•I•N•G S•P•O•T•L•I•G•H•T

Nestlé Smarties Brand switches to 100 Percent ng Recyclable Paper Packagi

arties d that its popular Sm Nestlé has announce for ing yclable paper packag brand is now using rec first cts worldwide. It is the its confectionery produ 0 brand to switch to 10 global confe ctioner y ing ov rem per packaging, percent recyclable pa sold million plastic packs approximately 250 globally every year. ed per packaging is sourc The new Smarties pa pe pa r de of a coated paper, sustainably and is ma tire . The transition of the en labels or carton board per pa le ab olio to recycl global Smar ties portf en tak s t the company ha packaging is a step tha tainable future. keeping in view the sus

Tensei Converts Bio-wast e into Paper Packaging

Tensei, the UK-based company, is a specialist in creating produc ts that use ag ricultural waste crops , perennial grasses, or unrealized bio -waste streams (from pla ces like the food manufacturing industry). They render ag ricultural residues such as – apple skins, avocado peels, an d mango peels into paper packag ing.

The foundation of Te nsei is premised on the intent to normalize the use of agricultural residue for packaging purposes, the objective being to tackle the de for estation crisis connected to sin gle -use plastic manufac turing.

Procter & Gamble Announces First Lenor Paper Bottle Pilot

Solenis and BASF to Work on Paper Bottles With Pulpex The specialty chemical firm Solenis has joined BASF as a par tner with Pulpex, a com pan y dev elo pin g full y rec ycla ble pap er bot tles .

Pulpex is developing a commonly recyclable, pol yeth ylen e tere pht hal ate (PET) free paper bottle using sustainably sourced pulp.

In a repor t, Pulpex has mentioned that BASF will contribute food-grade barrier chemistry. Solenis, which already serves the pulp and paper industry, will provide surf ace treatments and other chemical components.

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bottle for Lenor in P&G has unveiled its first paper com pan y Pab oco , par tne rsh ip with pap er bot tle Europe in 2022. The announcing a pilot for Western test and learn strategy trial rollout will form the basis of a incorporate it more to scale up paper packaging and widely across P&G's por tfolio. aims to reduce its As par t of its 2030 Ambition, P&G 2030. Fabric Care use of virgin plastics by 50 by ed to a 30 absolute Europe has additionally committ to design for 100 plastics reduction by 2025 and l on track for both recyclability by 2022 – it is wel mitted to using no commitments. Home Care is com packaging alternavirgin plastics by 2025. Brand-led cial elements in the tives and pilot schemes are cru tal impact. pathways to lowering environmen

P•A•C•K•A•G•I•N•G S•P•O•T•L•I•G•H•T

Flipkart and Myntra Join Hands with Canopy to Advance Sustainability Efforts and Conserve Forests Flip kar t Gro up, Ind ia's hom egr own con sum er internet ecosystem inc lud ing Flip kar t, and My ntr a, one of Ind ia's leading fashion and l i f es t yl e d es t i nat io n s , ann oun cing its com mitment to responsible ing and man-made cellulosic sourcing of sustainable packag profit environmental organifibers in collaboration with not-forzation Canopy.

Canopy's Pack4Good and Flipkar t and Myntra have joined r sustainability commitment CanopyStyle initiatives to extend thei ing and material sourcing. to move towards sustainable packag

Flipkart Achieves 100% Single-Use Plastic Elimination Packaging throughout its Supply Chain

Flip kar t has elim ina ted all sing le-use plas tic packaging used across its fulfi lment centres in India, delivering on its public com mitment to move to plastic-free packaging in its own supply chain by 2021. This has been achieved acro ss more than 70 facilities of Flipkart spread all over India, where the e-comm erce major has elim inat ed sing le-use plastic packaging by introducing the most scalable sustainable alternatives such as eco -friendly paper shreds, replacing poly pouches with recycled paper bags, replacing bubble wraps with carton waste shredded material and 2 Ply roll to name a few.

Noida-based Kagzi Bottles Introduces 100% Biodegradable Paper Bottle

Plastic packaging has long been the obvious choice for many liquid products brands — such as body wash, lotion, beverages, shampo o etc. Without a doubt, plas tic is durable, inex pensive and mos t importantly — it does not absorb liqu ids. However, as the awareness on the sustainable packaging rises — the consumers have star ted dem anding sustainable alternatives. That is where paper bott les come in.

Providing a solution to a very sign ificant and catastrophic environmental issue of single-use plastic, the homegrown Noida-based star tup is pioneering a com ple tely new pro d uc t c ate gor y: a 10 0 compostable paper bottle, which is also the first-ofits-kind in India. This innovative solution will give consumers a greener and cleaner switch from plastic to paper pulp. The bottle can be used to package beverages, toiletries, liquids and pow der.

Unilever Reveals World's First Papert Bottle Based Laundry Detergenleve r is set to launch

Uni what it says is the firstever paper-based laundry detergent bottle.

A prototype for the paper bot tle has been developed for leading laundry brand OMO (also known as Persil, Skip & zil by early 2022, with an Breeze) and is set to debut in Bra other countries soon after. ambition for roll-out in Europe and e technology to create paperUnilever is also piloting the sam based haircare bottles. d in par tnership with the Pulpex This technology has been develope Unilever, Diageo, Pilot Lite, consortium, collaboration between lever has been able to use the and other industry members. Uni ducts in first-of-its-kind papertechnology to package liquid pro ly made of sustainably sourced based bottles, which are reported the paper waste stream. pulp and designed to be recycled in

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P•A•C•K•A•G•I•N•G S•P•O•T•L•I•G•H•T

Parason Partners With Zume to Launch Most Advanced Molded-Fiber Manufacturing Facility in Southeast Asia

Jabil Announces USD 25 Million Investment in Paper Packaging Solutions

Parason, a leading global pulp and paper industry sup plie r, has ann oun ced the company's new manufacturing and professional services partnership with Zume, the sustainability solu tions company creating economically viable subs titutes for singleuse plastics. Parason will leverage Zume's proprietary manufacturing technology and professional services to support the production of molded-fiber goods in what will be the most advance d manufacturing facility of its kind in Southeast Asia .

As par t of this par tnership, Par ason is helping Zume further optimize stock pre paration and other aux iliar y systems that com plement the latter's core manufac turing tech nology. These effo rts enhance Zum e's cap abil ity to deli ver turnkey solutions globally with par tners eager to leverage Zume's manufacturing tech nology.

CHANEL Perfume Bottles With a Bio-based Cap Developed in Partnership with Sulapac

Jabil Inc. has a n n o u n c e d expansion plans for its newly acquired paper bottle tech nolo gy with a US D 25 m il l ion c's Manteca, California, investment in subsidiary Ecologi er bot tle pla nt in its and the build-o ut of a new pap in Tortosa, Spain.

Sustainability Center of Excellence first paper-based scaled The expansion will create the log ic's innovative pul p tech nology with deliveri ng Eco graphies, enabling the molding capabilities to new geo of new paper packages. production of hundreds of millions

se The Fre nch lux ur y fash ion hou new its CHANEL has announced that ml L ES E AU X DE C H A N E L 125 based per fume bottles will have a biowith ip rsh tne cap develop ed in par of ed pos Sulapac. The new cap is com 91 of three layers, apparently made ined obta ls eria mat ed percent bio-bas s urce reso sed from renewable, plant-ba and FSC certified wood chips.

EL's Fur ther, LES EAU X DE CHAN ed sign rede n ing has bee corrugated cardboard outer packag or ion by its lack of laminat simply. It is made easier to recycle pany. glossy coating, according to the com

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Mondi Introduces a Range of Sustainable Corrugated Packaging Solutions Mo ndi Gro up has introduced a range of corrugated packaging sol utio ns for the online g r o c e r y market across C e n t r a l Europe. Utilizing its experience in eCommerce packaging, the packaging com pany has created clever solutions for the diverse needs of grocery retailers who can now deliver a vari ety of goods in fitfor-purpose packaging.

All the corrugated boxes in the eGr ocery por tfolio are completely recyclable and mee t the customers' requirements of sustainability, cost -efficiency, and product protection.

The eGrocery packaging solutions follow the successful introduction of Mondi's BCoolBo x and VinoBoxes.

Grocery retailers can choose from the expanded portfolio of seven sustainable corr ugated packaging solutions for all kinds of grocery pick -up and delivery options – click & collect, local deli veries via retailers' own vehicle fleets, or long-distance deliveries.

P•A•C•K•A•G•I•N•G S•P•O•T•L•I•G•H•T

Burger King Rolls Out Green Packaging Pilot Program

Hasbro is Phasing-Out Plastic Packaging

Burger King has launched a gre en pac kag ing pilo t program focused on finding scalable solutions for eight of its most-used, guest-facing items incl udi ng fork s, spo ons , knives, straws, drink lids, napkins. The guest packaging Frypods, Whopper wrappers and as Frypods made with renewutilizes alternative materials, such cutlery made with cPLA, a able unbleached virgin paperboard; e with 100 percent recycled plant-based plastic; and napkins mad testing paper and plant-based fiber. Burger King will also be ch could potentially eliminate straws along with strawless lids, whi plas tic straws annually from up to 500 million single-use aurants. par ticipating U.S. Burger King rest al par tnership with Loop to The fast food giant is keeping its glob ugh reusables and is looking to reduce single-use packaging thro don, in addition to the earlier include two new cities, Paris and Lon York, Por tland, and Tok yo. announced target cities of New The Coca-Cola Company and Burger King is par tnering with es to life.

Kraft Heinz to bring these initiativ

Hasbro, the global play and entertainment company and the creator of iconic toys and games such as –Ner f, Transformers, PlayD o h, M o n o p o ly, and Power Rangers, is phasing out plastic from its packaging. The global toy compan y plans to eliminate all plastic packaging for new products by the end of 2022 and is introducing new pro ducts that will be sustainable.

In 2018, Hasbro became the first toy company to offer a recycling program for US cus tomers. In par tnership with TerraCycle, the company recycles the “retired” toys back into thin gs like playground equipment, park benches, and flow erpots.

Garnier Launches its Solid Shampoo Bar in Recyclable Cardboard Box

BillerudKorsnäs Launches New Generation of Coated Liner BillerudKorsnäs has introduced its latest development in White Top Kraftliner – Pur e De cor X™ .

Pure DecorX is a 3ply construction made of 100 percent primary wood fibers, which makes the liner strong, stiff and with high thickness. In practice, this mea ns great lightweighting opportunities, high runnability in converting machines, reduced risk of washboarding, and enhanced packaging per form ance.

Garnier has relau n ch e d i t s Ul t r a Do ux line of sha mpoos, which now come in a solid bar format, in rec yclable and FSC cer tifie d car dbo ard packaging.

According to the me dia rep or ts, the launch represents the Ga r n i er ' s f i r s t n o was te sha mp oo and edients pressed into a solid boasts 94 percent plant-based ingr available in five versions to suit shampoo bar. The shampoos are tic wrapping. all hair types and do not require plas Garnier presents a new line of With these Ultra Doux shampoos, of plastic packaging. It's yet sustainable beauty products free mitment to greener, and more another step forward in its com -cer tified cardboard, Garnier sustainable beauty. By using an FSC respects people and nature. suppor ts forest management that

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P•A•C•K•A•G•I•N•G S•P•O•T•L•I•G•H•T

Refillable Antiperspirant Cases Made With No SingleUse Plastic Packaging

In an effort to help reduce plastic was te, Secret and Old Spice have launched their inno vative refillable a n t ip e r sp i r a n t c as e s at s e l e c t r e t a il e r s .

Additionally, both brands will expand their offering of aluminum free deodorants in recyclable paper tube packaging made of 90 per cent recycled paperboard, certified by the For est Stewardship Council (FSC).

Available in refillable antiperspirant, the first from a major brand, this new produc t line now offers consumers a way to eliminate plas tic waste without compromising on 48-hour sweat protection.

BillerudKorsnas and Tetra Pak Together Aims to Achieve 100 Percent Recyclable Packaging

g col lab ora tion Thr oug h clo se and end urin aim to push the BillerudKorsnas and Tetra Pak wood fibre in figure of renewable material from per cen t. New car ton pac kag es tow ard s 100 sustainability of innovations to further increase the agenda for both packages are since long top of the companies. s the form of a The collaborative innovation take experts from the number of defined projects where two companies work together.

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IIT Roorkee Develops Food Packaging Paper From Pine Needle Waste

packaging, researchers In a move towards sustainable food address the issue of plastic at IIT Roorkee have found a way to plastics used in the food pollution caused by single-use develop ed an ethylene packaging industr y. They have pine needle waste. scavenging functional paper from best alternatives to wood, The pine needles are one of the waste would be a sustainand the paper developed from its used in food packaging. able substitute to single-use plastic

Zume Partners With Solenis to OpenSource Molded Fiber Packaging and Manufacturing Playbook Zume Inc., the sustainability solutions company creating eco nom ica lly viab le substitutes for singleuse plastics, has announced a par tnership with Sol eni s, a leading global producer of specialty che mic als. Bot h the companies are open-sourcing a PFAS (per- and polyfluoroalkyl substances) replacement for food packaging manufacturing to food manufacturers and CPG bra nds across the global market.

After nine months of deep collabo ration and R&D to create a solution that reduces the need for single-use plastics, Zume and Solenis are open-sourcing the reci pe and manufacturing process so that all packaging manufacture rs can adopt the technique and speed up the removal of harmfu l chemicals. This marks an important milestone for the indu stry, as two major companies unveil the complex process of crea ting a molded fiber packaging solution that ensures food grease and water resistance without the need for PFAS or harmful chemicals.

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Mitsubishi HiTec Paper Offers Sustainable Secondary Packaging With Barricote Barrier Papers

Mitsubishi HiTec Paper has been developing fully recyclable barrier papers for flexible food and nonfoo d pac kag ing sinc e Drupa 2016. A key player in the food industry has bee n usi ng bar rico te BAG WGOM for cocoa powder for many years, and for some time now barricote LINER MG for

te drops. secondary packaging for chocola

Holmen Iggesund Launches Paperboard Coated With Bio E Barrier Coating Solution Hol men Iggesu nd has launche d paperboard coated with Bio E, a barrier coating solution made from 75 percent renewable raw materials and app roved for ind ustr ial composting. Paperboard packag ing sol utio ns hav e com e as a welcome change for many food and beverage brands eager to reduce their use of plastic and improve thei r carbon footprint.

Kraft Heinz Reports Progress on Sustainable Packaging Goals

ial In its 2021 Environmental Soc ft Kra ort, rep G) Governance (ES it s gres pro the ed Heinz has describ of et targ its g has made in achievin , usin g 100 per cen t rec ycla ble kag pac reusable, or compostable its ing by 2025, while setting forth in s ne x t s tep s for i n nov at ion sustainable packaging.

report, most of Kraft Heinz's As per the findings of the ESG s glass or metal materials that packaging is paper-based, or use of its packaging is made up of are reportedly recyclable. The rest containers. Earlier this year, flexible plastic films or rigid plastic le paperboard cup for its Kraft Heinz also tested a recyclab Cheese product. microwaveable Kraft Macaroni &

Kotkamills and Siegwerk Partner to Create Innovative Solutions for Development of Fiber-Based Packaging Kotkamills and Siegwerk have joined forces to create innovative solutions for printers and pr o d uce r s o f f i b er- b ase d pac kag ing to fur the r driv e packaging circularity. Under t h e m o t t o “ To g e t h e r w e accelerate change for good”, this strategic par tnership aims to provide the market with highly sustainable and eco friendly solutions.

The collaboration is based on the pote ntial of water-based dispersion barrier coated paperbo ard to replace traditional polyethylene (PE) coated boa rd. Together the two par tners offer a viable alternative to replacing plastic coatings in fiber-based packaging, improving recyclability and circularity and resulting in an increased value of wastepaper, and improved fibre reco very. Their solutions are designed to help converters and brand owners to deliver more sustainable packag ing alternatives and thereby furthering Circular Econom y going forward.

ecycled, Mattel Achieves 97 Percent R d Fiber FSC-Certified Paper and Woo ing for Products and Packlag has surpassed its set

Matte intain goal to achieve and ma FSC95 percent recycled or paper certified content in the in its ed us and wood fiber in ing products and packag on us 2020. Through its foc umer ns co stpo maximizing king see d an recycled content, rd thi le credib ge of fiber certified by a to increase the percenta nt recycled or ed to source 97 perce iev ach s ha l tte Ma , rty pa packaging in used in products and FSC-certified content Rainforest Alliance.

2020, as validated by the port of its goal to make progress in sup The Company continues or bio-based nt recycled, recyclable, to achieve 100 perce 2030. ducts and packaging by plastic materials in all pro

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Flipkart: Strengthening Commitment to Sustainable Solutions for Packaging We have achieved a milestone of 100 percent elimination of plastic packaging and adoption of sustainable packaging alternatives across our own supply chain.

Mr. Mahesh Pratap Singh, Head - Sustainability and Social Responsibility, Flipkart

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lipkart is one of India's leading e-commerce marketplaces. Founded in October 2007, the company offers around 150 million products spread across 80+ categories. Recently, the e-commerce major announced that it has eliminated almost all singleuse plastic packaging used across its fulfilment centres in the country. This includes switching to eco-friendly paper shreds, replacing poly pouches with recycled paper bags, replacing bubble wraps with carton waste shredded material among others. Paper Mart got the opportunity to interact with Mr. Mahesh Pratap Singh, Head Sustainability and Social Responsibility, Flipkart and know more about the impact of sustainable packaging and the contribution of the company in this regard.

Paper Mart: Please shed light on the innovative and sustainable packaging solutions by your company. How are you strategizing to boost their adoption across your supply chain?

Mahesh Pratap Singh: Sustainability is one of the core tenets of our values and the way we conduct business at Flipkart. As we continue to grow and democratise ecommerce across India, we have made conscious efforts to incorporate sustainability across functions to reduce our environmental impact. With this thought, we doubled down on our sustainability initiatives and made a commitment to eliminate single-use plastic packaging from our own supply chain in 2019. In line with the efforts, we have achieved a milestone of 100 percent elimination of plastic packaging and the adoption of

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sustainable packaging alternatives across our own supply chain.

Additionally, in July this year, more than 75 percent of our seller fulfilled shipments have also now been processed in sustainable packaging marking a 20 times increase over July 2020. The initiative today covers more than 700 hubs across India. We have taken various steps in this journey, including analysing and studying circular economy models, looking at ways for packaging optimisation, creating national standards on packaging materials to reduce waste in our supply chain, promoting reusable materials, while encouraging green packaging.

Our sustainability journey has been marked by an orchestrated effort to create a positive environmental and social impact. This milestone was achieved by introducing the most scalable sustainable alternatives such as eco-friendly paper shreds, replacing poly

This milestone was achieved by introducing the most scalable sustainable alternatives such as eco-friendly paper shreds, replacing poly pouches with recycled paper bags, replacing bubble wraps with carton waste shredded material and 2 ply roll, to name a few.

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We have taken various steps in this journey, including analysing and studying circular economy models, looking at ways for packaging optimisation, creating national standards on packaging materials to reduce waste in our supply chain, promoting reusable materials, while encouraging green packaging. pouches with recycled paper bags, replacing bubble wraps with carton waste shredded material and 2 ply rolls, to name a few. Throughout this process, we have also ensured that we are fully compliant with all EPR regulations and through our network of recyclers, the equivalent quantity of single-use plastic going to consumers is fully recycled.

PM: How do you view the impact of sustainable packaging and your contribution in this regard?

MPS: Packaging is ubiquitous in everyday life and usage of traditional packaging has led to a strain on resources, environment and biodiversity due to the choice of materials used, lack of recyclable options and unsustainable disposal mechanisms. There has been an increasing focus from consumers, governments, brands, packaging producers on collective action to shift to environmentally friendly solutions and better waste management practices. Some of the quick wins that have helped most stakeholders have been reducing the quantity of plastic used in packaging, improving recyclability and innovations in materials used. These solutions will help reduce our impact on our ecosystems. However, to derive longterm value for a positive impact on the planet, there has to be a reconsideration of the packaging design itself to suit diverse applications. Packaging in the coming years needs to be more functional, designed to be recyclable, reusable and regenerative in nature.

To this effect, we have introduced 'E-commerce ready packaging', where 15 percent of products have been shipped without adding a secondary layer of packaging.

Flipkart's ambition is to reduce the need for an outer layer by working with brands across apparel, electronics and home furnishings to ship their products in the original manufacturer/brand packaging. We are also working towards making sure that the packaging used does not cause any deforestation by scaling packaging from recycled and alternative materials.

Additionally, we have also been working on initiatives

like sourcing or designing reusable/refillable shipping boxes, minimising the usage of packaging materials for resource efficiency, giving preference to packaging with high-recycled content, and sourcing packaging made from alternative fibres and supporting emerging circular solutions.

PM: As customers are increasingly moving towards eco-friendly shopping experiences; how do you view paper packaging as a resource-efficient product with the lowest environmental impact?

MPS: We have been actively collaborating working with various partners on long-term sustainability initiatives and have received positive customer responses on the successful implementation of greener alternatives like multi-use belts, recycled paper-based pouches, and carton waste shredded material. In phases, these have been replacing stretch film, polythene pouches, and plastic fillers such as bubble wrap and airbags. While we have ensured that the alternatives implemented possess a high degree of recyclability and reusability, we are constantly working to explore best practices including researching and applying emerging and circular economy innovations.

Given that usage of forest-based substitutes might give rise to environmental issues, we are working to avoid sourcing from ancient and endangered forests and develop conservation plans to protect them. We will also be exploring research and development of commercialscale production of packaging from alternative fibre sources. We are also encouraging our suppliers to continuously improve and expand the availability of recycled content in papers/packaging.

In the beginning, we did several pilots, and our teams came together for various trials and errors on possible alternatives. For instance, replacement of airbags with shredded paper l

A shredding or meshing machine converts corru-

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P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L industries in India having a country-wide presence.

We are also actively working with our seller partners, who fulfil customer orders directly from their locations to educate them and enable them to move towards alternative materials. gated boxes into mesh sheets, which are used as a void filler or cushion wrapper to protect products from transit damages. These machines were installed at all of our major fulfilment centers. Currently, no material is procured for void fillers and corrugated cartons received from brands are recycled. l

Invoice polybag replaced with paper pouch Ø Poly bags were being used for attaching customer invoices to packaging. The pouch has been replaced with a recycled kraft paper pouch. It is made of 100 percent recycled paper which gets further recycled leading to zero landfills. Ø Similarly, the plastic used for secondary packaging has been replaced with paper bags and multiuse polyester bags for reverse shipment processes.

To ensure that, we are looking at addressing material issues related to the broader packaging ecosystem, we have partnered with Canopy, a not-for-profit environmental organisation, for responsible sourcing of sustainable packaging and man-made cellulosic fibers.

We have joined Canopy's Pack4Good and CanopyStyle initiatives under which we will be focusing on the following activities: l

Exploring sourcing or designing of reusable/refillable shipping boxes to reduce corrugated paper and paperboard,

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Encouraging the use of recycled, reusable and/or FSC certified paper and packaging as well as sourcing products with responsibly sourced man-made cellulosic fibres,

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Designing and implementing systems that minimize the use of packaging materials,

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Increase utilisation of recycled materials in packaging,

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Utilise reusable packaging systems for intra-business applications,

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Increase the use of digital communication, marketing and accounting systems,

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Adopt best practices including researching and applying emerging and circular economy innovations,

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Increasing the use of responsibly sourced man-made cellulosic fibre for in-house products including rayon/viscose, lyocell, and modal.

PM: What kind of trends do you foresee in the coming years?

MPS: We expect further growth of optimised packaging systems that ensure minimal wastage of resources while at the same time, use of new-age materials such as agricultural residue for creating packaging is likely to be adopted well by the industry. There will be an increased focus on a higher degree of recyclability and reusability in packaging materials, thereby promoting circular packaging systems.

The circularity of packaging materials wherein all packaging can be upcycled into other products instead of going to landfills is inevitable, with refillable packaging emerging as a trend to watch out for. Sustainable design that will do away with the need to add a secondary layer of packaging for a product or use materials that can be repurposed for other use cases is sure to be the course of action in the coming years.

PM: What challenges do you face while procuring packaging materials and what expectations do you have from the packaging companies?

MPS: Sustainability is a journey, and the collective efforts of the ecosystem play a pivotal role in moving towards a low carbon economy in order to ensure that our solutions have a positive social and environmental impact. This assumes significance as we are building ecofriendly alternatives for one of the fastest-growing

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These efforts will further strengthen our commitment to sustainable solutions for packaging and realize our vision of sustainable growth. Accomplishing these goals will require collaboration on many fronts with our seller partners, suppliers, and other ecosystem players. We are also working with other stakeholders in the ecosystem to understand how we can best implement new innovations to tackle plastic waste and extend these efforts to thousands of seller premises for orders shipped directly.

PM: Functional packaging designs are a clever way to increase the value of any product and the overall customer experience. Tell us about your designs and the packaging material used for them.

MPS: As an environmentally responsible organisation, we are constantly piloting various solutions to ensure we meet the criteria of sustainability, affordability, availability and scalability across different products and materials. From water repellent coating on fully recyclable paper bags for an added layer of protection to using reusable belts instead of plastic stretch films and

P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L corporations alike for their scalability, availability and affordability. The final alternatives implemented have unique characteristics and some are industry-first in-house designs. These initiatives help ensure we provide the best solutions for our business, our community of marketplace sellers while bringing a delightful e-commerce experience to millions of customers across the country. We will continue to open-source our solutions and criteria to ensure independent and innovative solutions to be tested by our sellers as well.

recycled kraft paper pouches over invoice polybags, we have been able to come up with sustainable packaging solutions which also help reduce wastage and landfill.

We are also using paper bags instead of secondary plastic packaging and multi-use bags for reverse shipments. We are constantly trying to innovate and find better and more circular solutions that positively impact the environment and meet the objectives of our use cases.

Our design team evaluated options from innovators and

We are also actively working with our seller partners, who fulfil customer orders directly from their locations to educate them and enable them to move towards alternative materials.

They have been having a good experience switching to green packaging due to its ease of disposal and recycling. They have also reported an improvement in customer feedback since they started using eco-friendly packaging.

Furthermore, we have also been collaborating with the ecosystem to understand how it can best implement other initiatives to create a more circular economy for plastics so that the entire ecosystem can move towards a more sustainable future.

Stora Enso Invests in Expansion of Board Production at its Skoghall Mill

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Following the investment, the packaging board production capacity at Skoghall can be increased by approximately 100,000 TPA to a total capacity exceeding 900,000 TPA. The project is slated to be concluded by the second half of 2023.

October 26, 2021

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tora Enso has announced an investment of around USD 112.56 million (EUR 97 million) to expand the board production at its Skoghall mill site in Sweden. In addition, the packaging company is initiating a pre-feasibility study in order to convert the second line, which is currently idle, at its Oulu site in Finland, to a packaging board line.

The proposed investment in Skoghall is projected to further provide an impetus to attain profitable growth in attractive end-use segments, such as liquid packaging board and coated unbleached kraft. The project is expected to be completed by the second half of 2023. After the execution of the project, the packaging board production capacity at Skoghall can be increased by approximately 100,000 TPA to a total capacity exceeding 900,000 TPA. The investment decision has been made after the conclusion of the feasibility study which was announced in November 2020.

The board expansion in the Skoghall site will be carried through debottlenecking of one of the existing production lines.

After the successful transformation in the Oulu site from paper to kraftliner production, Stora Enso has decided to initiate a pre-feasibility study to convert the second, idle paper line into

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Skoghall Mill (Image: Stora Enso)

a packaging board line. The conversion would further improve the Oulu site's competence, with integrated pulp availability, additional fixed and variable cost savings, and the ability to utilise the adjacent deep-sea harbour. The pre-feasibility study will be completed in early 2022.

Presently, the total production of boards at the Skoghall site surpasses 800,000 TPA. n

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McDonald's: Implementing Solutions to Expand the Reduction, Reuse, and Recycling of Guest Packaging Our innovative and sustainable fiber packaging solutions include paper straws, easy-open & tamperevident stickers for carry-out bags, and tamper-evident labels for cups in delivery.

Mr. Rajeev Ranjan, COO, Connaught Plaza Restaurants Pvt. Ltd.

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opular food chain McDonald's recently announced that the company has almost achieved its goal of sourcing all of its paper food packaging in restaurants from recycled or sustainable fiber in its Purpose and Impact Progress Report-2020-2021. The company claims that 80 percent of its packaging came from renewable, recycled or certified sources in 2020, and 25 percent of its restaurants in the company's 30 largest markets offer customers the opportunity to recycle packaging materials. Further, the US-based quick service restaurant (QSR) chain has set goals to source 100 percent of its guest packaging from renewable, recycled or certified sources. Paper Mart got the opportunity to interact with Mr. Rajeev Ranjan, COO, Connaught Plaza Restaurants Pvt. Ltd. and know more about the packaging strategies of McDonald's.

Paper Mart: McDonald's is sourcing 99.6 percent of its paper food packaging from recycled or sustainable fiber. Please outline the efforts made by the company with respect to incorporating innovative packaging solutions.

Rajeev Ranjan: All centrally sourced packaging in McDonald's North and East India is Chain of Custody (CoC) certified, with 100 percent of wood fiber coming from recycled sources or forests certified to the Forest Stewardship Council (FSC) standard, a globally recognised standard for responsible forest management.

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Essentially, the Forest Stewardship Council (FSC) sets standards for and promotes environmentally responsible, socially beneficial and economically viable management of the world's forests. Wood and paper products labelled as FSC certified are high standards products and the flow of the material can be monitored from the forest to the end product. This is known as the Chain of Custody.

FSC certified fiber has been our primary material replacement for plastic packaging in the Indian market.

Driven by our efforts to reduce conventional single-use plastics, supported by legislative pressure in certain areas, we have decided to transition away from plastic bags, plastic straws, plastic cutlery, and plastic cups.

We continue to work with our partners and suppliers in developing new innovative materials and technologies such as moulded fiber. Our innovative and sustainable fiber packaging solutions include paper straws, easyopen & tamper-evident stickers for carry-out bags, and

Over the last 4-5 years, our efforts on introducing sustainable solutions in guest packaging have resulted in an overall annual reduction of 15 metric tons of plastic annually.

P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

Our innovative approach to packaging design means we have been able to roll out a wide range of new paper-based products in India and we plan to introduce many more in the next few years. tamper-evident labels for cups in delivery. Additionally, for our lids, we are currently using bio-based plastic material (PLA) which can be industrially composted.

PM: How does your company view paper packaging as a resource-efficient product with the lowest environmental impact?

RR: Paper packaging accounts for more than 80 percent of all packaging, including over 50 items of paper bags, paper cups, paper straws, and paper boxes. Our packaging strategy is based on maximising the use of Chain of Custody certified fiber for our paper packaging products.

These Chain of Custody certified products help us reduce our environmental footprint and reflect our preference for fiber over plastic packaging. We have also initiated work to validate 100 percent recycled fiberbased carton board for packaging as a step towards a circular economy and improved recycling.

Over the last 4-5 years, our efforts on introducing sustainable solutions in guest packaging have resulted in an overall annual reduction of 15 metric tons of plastic annually. Transitioning to FSC certified materials has resulted in approximately a 16 percent reduction in plastic use against a 2017 baseline.

PM: Could you please share an overview of paperbased material used for the packaging of your products?

RR: McDonald's packaging suppliers use a wide range of fiber, carton board and paper in the production of our food service packaging. All these materials are manufactured while ensuring that they are fully compliant with local and regional food contact specifications.

PM: What factors should be considered while choosing paper packaging material for food products?

RR: McDonald's food packaging is designed to protect our food products and maintain heat whilst reducing moisture, ensuring that paper packaging is 100 percent food safe and providing the necessary barrier or resistance to grease and oils.

Along with the certification of the materials used in the production of the paper packaging, the qualification and certification of the manufacturers and the materials

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used in the construction of the final printed packaging are critical. Food safety is the number one priority.

Alongside this requirement, designing packaging for end-of-life is also important. Utilising the appropriate printing inks and glues to enable fiber recovery needs to be embedded in the final specification.

McDonald's also prioritises recycled materials over virgin, subject to direct food contact testing and approval, and our minimum fiber sourcing requirements are FSC certification, in alignment with our commitment to eliminate deforestation across our supply chains.

PM: As a socially and environmentally responsible food chain – what could be the ideal roadmap to further boost the growth of sustainable and paperbased packaging?

RR: McDonald's continues to increase the number of sustainable fibers packaging products, replacing problematic plastics wherever possible. Our innovative approach to packaging design means we have been able to roll out a wide range of new paper-based products in India and we plan to introduce many more in the next few years. This includes more renewable fiber coatings that are easy for recycling, reduce plastic content and help meet the end-of-life requirements as per local legislation. We are also introducing innovative technologies such as moulded fiber to replace current biopolymer lids, heat seal lids, and moving from clamshells to wraps to reduce packaging waste.

PM: McDonald's has set a larger goal for its entire customer packaging to come from renewable, recycled, or certified sources by 2025. What kind of trends do you foresee for food packaging?

RR: Globally, McDonald's expects to increase the use of Chain of Custody certified fiber across the complete packaging portfolio and implement global and local solutions across the business to expand the reduction, reuse and recycling of guest packaging.

P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

Myntra: Initiating a Pathway for Seamless Adoption and Transition to Sustainable Packaging across the Value Chain Packaging offers a visible and tangible indication of our commitment to creating a sustainable ecosystem and moving towards a 100 percent elimination of singleuse plastic is a major step and a significant milestone in the direction of sustainable practices.

Ms. Neetu Jotwani, Vice President-Product Development & Sourcing, Myntra

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n integral part of Flipkart Group — Myntra is a major fashion e-commerce company. Recently, in a path-breaking move, Myntra has eliminated 100 percent single-use plastic in packaging. In an exclusive interview with Paper Mart, Ms. Neetu Jotwani, Vice President-Product Development & Sourcing, Myntra, talks about the steps and measures taken in tandem with the company's efforts to align its brand partners to adopt green packaging which has the lowest environmental impact.

Paper Mart: Please shed light on the innovative and sustainable packaging solutions by your company. How are you strategizing to boost their adoption across your supply chain?

Neetu Jotwani: Myntra's sustainability journey has been marked by an orchestrated effort to create a positive environmental impact. With the goal of going 100 percent plastic-free with the packaging achieved, Myntra is set to leave a profound mark on the industry.

One of our earlier key initiatives in this direction includes partnering with Canopy, a not-for-profit environmental organization, to ensure that the packaging used does not encourage deforestation by scaling packaging from recycled and alternative materials.

We place a strong emphasis on sustainable and responsible business practices by being emphatic in our mission of

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going plastic-free. Packaging offers a visible and tangible indication of our commitment to creating a sustainable ecosystem and moving towards a 100 percent elimination of single-use plastic is a major step in the direction of sustainable practices. As a leading player in the fashion, lifestyle and beauty space in the country, we have taken the lead in enabling our seller ecosystem to adopt sustainable packaging alternatives along with us, creating a positive environmental impact across the entire supply chain. In addition to its own supply chain, Myntra's sellers have also adopted the green packaging defined by Myntra. This milestone is a significant outcome of the efforts initiated by the company towards aligning its seller partners and helping them with a transition path to gradually adopt sustainable packaging alternatives.

In an industry-first for any fashion and lifestyle e-commerce brand operating at scale in India, Myntra has introduced scalable and sustainable alternatives for packaging and delivery… This move has led to the diversion of 670 tonnes of plastic, as of September 2021.

P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

PM: How do you view the impact of sustainable packaging and your contribution in this regard?

NJ: In an industry-first for any fashion and lifestyle ecommerce brand operating at scale in India, Myntra has introduced scalable and sustainable alternatives for packaging and delivery, such as replacing poly pouches with recycled paper bags, bubble wraps with carton waste shredded material and plastic adhesives tapes with paper tapes, polybags used for attaching customer invoices with a recycled Kraft paper pouch and RFIDtagged multi-use polyester bags, piloted for reverse shipments as packaging materials. This move has led to the diversion of 670 tonnes of plastic, as of September 2021. The pioneering innovations implemented in packaging that eliminate the use of plastic are also in compliance with national and state regulations.

This has been achieved as a result of the commitment of multiple in-house teams and their methodical approach, involving several months of suitable material and process exploration, and collaboration with several ecosystem stakeholders. They included brand partners and sellers in order to ensure that alternative processes and methods being adopted were adept at handling the scale and specific requirements of the e-commerce supply chain, in addition to being sturdy enough to handle different product categories.

PM: As customers are increasingly moving towards eco-friendly shopping experiences; how do you view paper packaging as a resource-efficient product with the lowest environmental impact?

NJ: In an initiative to enable customers with the choice to adopt and shop sustainable fashion and lifestyle, Myntra started a dedicated platform – 'Myntra for Earth' store.

There are about 70 leading fashion and lifestyle brands to offer more than 5500 styles to customers on this sustainable store. The products ordered through this store are delivered in packets made from 100 percent recycled paper.

At Myntra, we believe that sustainability is the way forward. In our unwavering commitment and focus towards creating an environment-friendly future for the

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We have partnered with not-for-profit organization Canopy to source sustainable packaging. Through this partnership, we ensure that the packaging used does not encourage deforestation, by scaling packaging from recycled and alternative materials. generations to come, we've implemented sustainable measures to reduce our carbon footprint, and offer conscious and sustainable fashion choices to our customers. Thus, our transition towards paper-based packaging has been a natural culmination of our efforts in adopting sustainable practices and lowering our environmental impact.

PM: How do you ensure the selection of the most scalable solutions with regard to sustainable packaging? In what ways do you facilitate in the seamless adoption of sustainable packaging for the sellers at your platform?

NJ: In a bid to extend our commitment towards sustainability, we have partnered with not-for-profit organization Canopy to source sustainable packaging.

Through this partnership, we ensure that the packaging used does not encourage deforestation, by scaling packaging from recycled and alternative materials. As signatories of Canopy's Pack4Good (packaging) and CanopyStyle (fashion) initiatives, we will shift towards sustainable sourcing of forest-derived products and pilot alternative next-generation solutions to transition away from forests for raw materials. In the next three years, we will focus on exploring sourcing and designing of reusable or refillable shipping boxes to reduce corrugated paper and paperboard and encouraging the use of recycled, reusable and FSC-certified paper and packaging.

Further, to facilitate faster adoption of paper bags in the packaging value chain and to ensure that the sellers get them at a regulated price and optimal quality, we've equipped the seller portals to enable sellers to place orders directly for the bags. The journey towards achieving this milestone also included prototypes of the alternatives being tested for six months to choose the most scalable and affordable systems. We ensure that all fulfilment centres are equipped with the right technology and adequate infrastructure including machine

P•A•C•K•A•G•I•N•G S•P•E•C•I•A•L

Another key initiative by Myntra along with the brand partners, includes, 'Ecommerce-ready packaging', which is a sustainable program aimed towards doing away with the need for a secondary layer of packaging in ecommerce shipments customisation to carry out the goal of sustainable packaging in entirety.

PM: Functional packaging designs are a clever way to increase the value of any product and the overall customer experience. Tell us about your designs and the packaging material used for them.

NJ: We have recently pioneered a solution for adapting existing machines designed and built to run plastic bags only, to now process paper packaging. To ensure 100 percent adoption of the same, a unique QR code scanning was implemented for each bag to prevent any inadvertent use of

plastic bags instead of paper bags. Bubble wraps, plastic cello tapes and poly covers have been replaced with shredded materials, paper tapes and paper covers and boxes respectively.

In this direction, another key initiative by Myntra along with the brand partners, includes, 'Ecommerce-ready packaging', which is a sustainable program aimed towards doing away with the need for a secondary layer of packaging in ecommerce shipments permanently and shipping products directly in primary packaging.

Paper Industry Concerned Over Increase in GST on N•E•W•S Paper Bags, Cartons and Boxes: IPMA IPMA is of opinion that an increase in the GST rate on cartons, boxes, bags, packing containers of paper will discourage weaning away consumers from single use plastic.

September 20, 2021

I

ndian Paper Manufacturers Association (IPMA) has expressed concern over increase in GST rates on paper bags, cartons, boxes and other packaging media which according to the association will make it expensive for consumers to shift away from single-use plastic.

The GST Council, in its 45th meeting held on 17th September 2021, has recommended an increase in the GST rate on cartons, boxes, bags, packing containers of paper etc. from 12 percent to 18 percent.

According to the Indian Paper Manufacturers Association (IPMA), this recommendation of the GST Council is surprising and not in sync with the move of the Government towards ban on the use of single-use plastic. Recognising the global menace of single-use plastic which is not biodegradable, India had earlier given an international commitment to ban all single-use plastic by 2022. Last month, towards this endeavour, the Government of India amended the Plastic Waste Management Rules prohibiting the manufacture, sale and use of several single-use plastic commodities from 1st July 2022; and also prohibited the use of plastic carry bags with thickness less than 75 microns with effect from 30th September 2021 and 120

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Paper Packaging

microns with effect from 31st December 2022.

IPMA President, Mr. A S Mehta stated that paper is one of the most environmentally sustainable products as it is fully biodegradable, recyclable and is produced from sources which are renewable and sustainable. Paper provides a viable alternative to single-use plastic in several applications. An increase in the GST rate on paper cartons, boxes and bags will work against the Government's efforts towards phasing out the use of single-use plastic, he added. n

S•U•P•P•L•Y C•H•A•I•N

Supply Chain Management in the Pulp and Paper Industry On the way to reliable sustenance with continuous reduction in freight and handling costs.

Author: Dr. Deepak Kumar Khare, Vice President- RM, BGPPL, Gurgaon

T

he pulp & paper industry (Forest-Based Industries-FBIs) in India post-implementation of the National Forest Policy 1988 have faced tremendous challenges in sourcing their raw material (RM) – wood and bamboo. The government's support to source raw material was withdrawn indicating that the industries are to source their RM on their own. There has been a long challenging 33 years of progressive and emphatic journey so far; the pulp & paper industry has evolved and grown a lot.

About 50 years before, the fiber primarily used was bamboo and mixed hardwood, which was mainly sourced from government-owned forests.

Comparing today's cost of production and the quality of fiber, earlier, the

quality was very poor and the cost of production was also high with high chemical consumptions and lower yield, though paper was accepted by the market since paper market was mainly the sellers' market. Over a period of time, the market has grown to be globally competitive with lesser cost of production and exceptionally demanding quality of paper. In India, with the continuous adoption of improved global technology, the Indian paper industry has kept pace and is expanding its global footprint though the cost of production is still high especially when we consider RM costs.

Demand and Supply Dilemma for Indian Pulp & Paper Industry The existing capacity requirement of RM is around 12.5 million MT per annum for the pulp & paper industry in India. With my own assessment, about 10 million MT per annum is required by other FBIs like plywood, MDF and poles (organised and unorganised) leading to an overall demand of about 22.5 million MT per annum.

If we observe historically, the availability of raw materials is a cyclical process and its prices get impacted accordingly.

Having an assured supply for any forestbased industry in India has always been a concern and the prices are governed mainly by demand and supply.

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Industries have progressed by generating their own RM near their own catchment and protecting it by assuring viable lucrative prices to farmers so that they continue to plant and maintain coppicing crops in the long run to enhance their income by the way of supplying to pulp & paper industry.

Backward Supply Chain with Reference to Raw Material (Wood & Bamboo) Wood and bamboo are biological products and these are grown on far mer s' land s provid i n g m u c h needed sustainable rural employment all throughout its backward supply linkages beginning from raising plants at nursery/CPC, site preparation, planting, protecting, harvesting and transporting to reaching the consumers. Challenge or threat as perceived by FBIs post NFP 1988 to arrange their own raw material got converted to an opportunity by encouraging farmers to plant eucalyptus, poplar, casuarina and subabul on their own land, has turned out to be a boon for the industry. Most of the units have developed or are in the process of developing their own decentralized cost effective self sustaining catchment with the vision to overcome the biggest challenge of assured raw material supply.

S•U•P•P•L•Y C•H•A•I•N Overcame Challenges in Managing Raw Material Supply Chain – Success Story 1. Lower yield per acre- Yield enhancing Research & Development programme.

2. Higher Gestation period- Reduced through Research & Development 3. Availability: Sustained & Assured RM Supply throughout the year.

4. Manual Labor dependent operations-Explored mechanized operations and implemented.

5. Continuously reducing carbon footprint- reducing distance of sourcing-reduced consumption of fossil fuel 6. Handling in Mills Yard- Enhancing load ability of trucks / tractor trolleys - Sustaining production without interruptions.

Evolution of Wood Yield/ Acre and Gestation Period of Tree Crops – Enhancing Financial Viability Considering the period of 1988-89 when farm forestry began, it was not a smooth go-getter amongst farmers.

Tree crops were seed rooted with excessive genetic variation with a rotation of 7-8 years yielding about 1012 MT per acre. Acceptability of farm forestry efforts amongst farmers was very poor as tree crops had long gestation periods with low yield which was not lucrative to farmers. Against these odds, the industry continued to make efforts to overcome these challenges. Various global success story learning were incorporated like selection of site-specific, genetically superior, high yielding eucalyptus/poplar “Candidate Plus Trees” (CPTs), testing of the CPTs were conducted with finally selection of successful clones it took about 13-15 Years to reach favorable stage of

reducing gestation period from 7-8 years to 3-4 years and improving yield from 10-12 MT per acre to 35-40 MT per acre. Simultaneously, casuarina and subabul tree improvement programmes too have been successfully incorporated amongst farmers.

Various viable and successful agroforestry, agri-horti-forestry models have been introduced with intercropping of wheat, soyabean, tobacco, chilli and with various vegetables which has resulted in further improved financial viability for farmers.

Secondly, with the improvement in yield per acre, the requirement of land for raw material gets reduced. In other words, the higher availability can be fetched from the same quantum of land. These efforts have resulted in successful covering of three main pillars of sustainability viz. financial (benefits to farmers and Industries), environment (sequestering additional carbon), and social (providing regular employment to rural communities).

Pulpwood Seed rooted and Clonal plantation To improve productivity and to reduce gestation period

Clonal Plantation

Efforts to Ensure Long Term and Sustained Availability of Raw Material The pulp & paper industry with above mentioned efforts have resulted in the acceptability of pulpwood crops amongst farmers as any other agriculture crop, which give them continuous returns and protect farmers against any natural vagaries. The overall cumulative planting has taken place more than the overall demand of the mills even to the extent of planting 120,000 Hectares in a year: IPMA. In addition to fulfilling their own requirements, the pulp & paper industry has supported the demand of plywood/MDF manufacturers and have also provided supplies to poles market which is quite unorganised, consuming huge quantum of eucalyptus and casuarina wood. Eucalyptus and subabul are coppicing crops which add to the additional availability during their due cycle of harvesting.

Evolution of Wood Harvesting From labor intensive to partial mechanized – From Axe to hand saw to power chain saw and from manual debarking to mechanized debarking Seed Rooted Plantation

The harvesting of wood or bamboo is highly labour-dependent. About 15-20

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S•U•P•P•L•Y C•H•A•I•N years ago, factors like harvesting l a b o u re r s ' ava i l a b i l i t y, a n d t h e affordability of the cost was not a concern. Gradually, with the opening of various avenues, migration of rural labourers to urban areas, and initiation of various government schemes and other freebies resulted in the shortage of overall labours. The Indian pulp & paper industry geared up long before as it anticipated such challenges well in advance and started exploring mechanization at feasible stages of harvesting from 2009-10.

Wood harvesting involves cutting of trees, billeting to the desired sizes, debarking, loading of the billets into the trucks and finally transporting to the consuming mill sites. Initially, cutting of trees was done through axes which was slower and inefficient, leading to wastage of wood. The introduction of mechanization was firstly through power chain saws which led to the reduction of about 5 percent labour and enhanced higher recovery of exploitable wood though it was miniscule per MT of wood, say about 0.5- 1 percent. Still considering the harvesting of about 22 million MT of wood annually, it is about 0.2 million MT. Countries Like Brazil have complete harvesters where trees are cut, debarked and cut into billets of uniform sizes in a few minutes. In such countries, pulpwood plantations move into thousands of hectares at a stretch, providing cost feasibility of holistic mechanization in terms of efficiency and huge scalability involved from a single site.

Pulp & Paper Industry Interventions- Wood harvesting in India

Harvesting through Axe (Wastage of wood)

Pulp & Paper industry interventions- Mechanized wood debarking in India

Manual Debarking

Harvesting Through Power Chain Saw (conservation of Wood)

Bark Wood Fed to Mobile Debarker Through PTO Driven Tractor

Debarked Wood Loaded Into Truck

Plantations harvested through power chain saw- minimal felling waste

Out of various harvesting stages, debarking of wood is a rate determining stage which is the slowest and consumes higher cost. To overcome this, during the year 2009-10, exploration and development of debarkers considering the Indian conditions began and in about 2 years' time, rotor mobile debarkers were introduced commercially, gradually replacing manual debarking. It has enabled in providing savings of about INR 200/MT and the ability to keep pace with the demand of debarked wood.

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Debarked Wood Visible In Debarkers

S•U•P•P•L•Y C•H•A•I•N Continuously supporting reduction in transportation costs and carbon footprint Pulp & Paper industries fiber sourcing strategy continuously improved and evolved with a vision to develop its resources nearer to their respective mills of which encouraging results have been achieved with reduction in average procurement distance from 700-800 Kms to 250-300 KMs, resulting in reduction in transportation cost.

Considering current freights, it provides cost advantage – savings of about INR 700-800/MT compared with previous landed price of total procurement.

Secondly, trip-wise carbon emissions (reduction in usage of fossil fuel) too have reduced contributing towards the betterment of the environment.

Another highlight of the pulp & paper industry's massive farm forestry

programme is that it has resulted in protecting forests indirectly. Villagers who used to venture in the forests for pilfering head-loads of fuel wood have started getting the lean waste wood and bark at their doorstep, thus, the pilferage from forests has reduced leading to regeneration of rootstock and green cover.

Raw material handling in mills yard More or less all the mills have advanced to mechanized yard handling operations whether it's feeding to chippers through static grabbers or handling at yards through mobile grabbers. It has resulted in huge reduction in manpower deployment and has given comfort in smooth and uninterrupted running of chippers.

Along with the successful implementa-

tion of mechanized operations in the yard, load ability and handling of tractor trolleys too have been worked, ultimately keeping pace with the ever increasing RM handling in various mills, ensuring cost reductions and improvement in efficient operations.

Conclusion – the Way Forward The Indian pulp & paper industry's passionate efforts especially with respect to building a robust, sustainable, reliable and cost reducing supply chain has paved the way to survive from the challenging times of the previous 25-30 years. This has resulted in a reliable supply sustenance of raw materials with reduction of about INR 1000-1200/MT in the overall supply chain beginning from farmers' fields to mills' chippers. n

Grasim Industries' Harihar Pulp Mill Orders an Evaporation Line Rebuild From Valmet

N•E•W•S

Valmet's delivery includes two new evaporation effects units based on Valmet Vapor Recycling technology, which is a proven solution for high dry solids operation without medium pressure steam. Engineering services and site services are also included in the delivery.

September 28, 2021

V

almet will supply an evaporation line rebuild to Grasim Industries Limited's Harihar Polyfibers pulp manufacturing mill in India. The rebuild project is designed to improve the evaporator reliability and to handle the increased plant capacity to suit Grasim Industries' pulp production expansion plans in the future. Improving the quality of the secondary condensate recycling will reduce energy and water consumption.

The order is included in Valmet's orders received of the third quarter 2021 and the start-up is scheduled for the third quarter 2022.

“We are aiming to increase the capacity and the energy efficiency of our pulp production line to meet the future needs.

We selected Valmet as our partner to deliver the rebuild project with advanced evaporation technology,” says Mr. Ajay Gupta, Unit Head, Harihar Polyfibers Unit, Grasim Industries Limited.

“We are able to offer clear improvement through our advanced evaporation technology with customized and detailed rebuild solution designed by our technical team. We are looking forward to a successful rebuild with our customer,” says Mr.

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Grasim Industries' Harihar Pulp Mill

Varun Jain, Director, India Region, Valmet.

The Harihar unit was the first manufacturing plant in India to use indigenous wood resources with in-house technology. It manufactures VSF and rayon grade pulp, the raw material for VSF. To make the process more sustainable, the unit produces rayon pulp with an innovative oxygen bleaching process that reduces the use of chlorine. n

P•R•O•D•U•C•T W•A•T•C•H

Retention and Drainage Improvement with AI/IoT Based Closed Loop Control It is a zero discharge system as there is an acute shortage of freshwater throughout the year. This water scarcity has forced mills to use recycled water with high dissolved solids for wet-end additives preparation. This was the biggest challenge for HABER to show a significant improvement in program performance while ensuring the stability of the wet-end system.

Author: Mr. Arjunan P N, Co-Founder and Vice President at Haber

Background Information A duplex board customer was running a retention and drainage aid program using a conventional control system for more than a decade. The Customer wanted to improve the program performance and reduce variations using the latest automation control techniques. HABER approached the customer and had a detailed technical discussion to understand the requirements followed by a thorough system study.

Haber Approach HABER has done a detailed system survey followed by lab evaluation using Britt Dynamic Jar and Drainage Tester for screening a suitable program keeping furnish and machine configuration in mind. Lab evaluation was repeated on different days to check the consistency of results considering the variation in furnish. Based on a detailed lab study, HABER had suggested a two-component retention and drainage aid program to achieve improved retention as well as drainage.

HABER adopted the below approach for program implementation: • The program was started up after a thorough cleaning of the system.

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P•R•O•D•U•C•T W•A•T•C•H

W H I T E WAT E R CONSISTENCY

DRAINAGE 500

0.25

475

400 300

0.25

0.2 340

0.15

200

0.1

100

0.05

0

0

Previous Program

0.16

Haber Program

• A fully automated eLIXA® controlled chemical preparation and feed system are used for coagulant and flocculant.

• Installed sensors for real-time measurement of pH, C o n d u c t i v i t y, Te m p e r a t u r e , a n d W h i t e w a t e r Consistency.

• Real-time measured values as well as offline data are uploaded to eLIXA® cloud and based on cloud data analysis, the chemical dosage optimization is done.

Customer Advantage • After one week of starting the program, whitewater consistency was less by 21% compared to the previous programs and is maintained well within the target range.

• Drainage improved by 15% and resulted in reduced steam demand in the drying section resulting in an increase of production rate by 5%.

• Overall retention improvement has reduced the solids going to the wastewater treatment plant. This has improved the efficiency of the wastewater treatment plant and ensured minimum colloidal substances and suspended solids getting circulated in the system. Since it is a zero discharge system, this improvement helped reduce the problems related to spoilage, stickies, and odor in the paper machine system significantly.

• Because of the consistent performance of the RDA improvement program, sludge generation has come down drastically, giving great relief to the customer in solid waste disposal management as the sludge has a very high amount of inorganic which cannot be used in the process nor in the boiler.

• A significant improvement in overall retention has increased the yield by 3% and reduced the downtime by 95% because of stickies-related issues. n

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3%

Increase in yield due to improved overall retention

5%

Increase in production rate due to improved drainage

94%

Reduction in base sheet defects due to clean whitewater loop

T•E•C•H T•A•L•K

Kemira Glyoxalated Polyacrylamide (GPAM) Multi-Function Development in APAC Pulp & Paper Industry APAC Pulp & Paper industry growth is driven by strong Packaging & Board, and tissue market needs, more than 8 million tons of new capacity started up in 2020-2021.

However, recycled raw materials quality variation, high COD and conductivity loading due to less fresh water consumptions become major challenges to most of the paper makers and chemical suppliers.

Current wet end and surface chemistry met their limitations on strength, drainage and runnabilities, as well as the weak tolerance to furnish quality variation and conductivity enrichment. How to open the existing operation window and achieve a new balance of wet end are focused directions for paper chemistry development.

Glyoxalated Polyacrylamide (GPAM) is developed and commercialized by Kemira for years. GPAM application started from tissue and containerboard strength enhancement but with less than one-month shelf life.

Kemira was able to develop the 2nd generation of GPAM with equal performance and up to 4-6 months shelf life, which expanded the opportunities to more paper grades and applications in larger regions.

Introduction Unlike the global Pulp & Paper industry flat trends, APAC shows continuous growth now and in upcoming 5 years driven by strong Packaging & Board and tissue market needs. However, challenges also went serious due to sustainability requirements. Bad or varied quality furnishes and less fresh water allowance squeezed the operation window of most of the wet end chemistry performances.

Kemira spent many years developing Glyoxalated Polyacrylamide (GPAM) product and application technologies, aiming to break through existing wet end limitations and build up a more robust system against variations.

In this article, you can find GPAM chemistry, new generation product properties, multi-function application knowledge sharing in different paper grades.

Glyoxalated Polyacrylamide (GPAM) Mechanism

There are 3 well proven applications from Kemira GPAM: 1.

Strength or multi-function booster for container board;

2. Drainage and runnability booster for virgin paper or board; 3. Dry strength and temporary wet strength for tissue.

Cost efficiency, easy to use (pump and go), multi-function application experiences and long shelf life all supported its success in the Pulp & Paper industry. The key benefits are breaking through existing wet end limitations and robust system establishment against variations.

Kemira Americas has mature GPAM market with more than 60,000 t/a in the last decades; Kemira APAC also built up volumes to 20,000 t/a in last 5 years supported by 2 production plants (China, Vietnam), good shelf life allows Kemira to spread GPAM business to the whole Southeast Asia Pacific.

Following the market and long-term needs, Kemira is under GPAM volumes expansion in APAC and onsite GPAM technology development for big consumers of strength and/or drainage.

Fig 1: GPAM mechanism Acrylamide copolymerization with DADMAC to produce cationic polyacrylamide intermediate, then reaction with glyoxal to produce final Glyoxalated polyacrylamide (GPAM) resin.

GPAM Self-Crosslinking (Figure 1 above part) : •

The glyoxalation of polyacrylamide to form amidol bonds;

•

The amidol groups further glyoxal among polymer chains to form a network structure. www.papermart.in / August-September, 2021 | 101

T•E•C•H T•A•L•K

GPAM reaction with fiber (Figure 1 below part): •

Aldehyde group react with hydroxyl group from cellulose to form hemiacetal bonds;

•

Hemiacetal bonds further react with cellulose to form acetal bonds.

Kemira New Generation GPAM New generation of Glyoxalated Polyacrylamide with high solids, cationicity and shelf life (Figure 2). Reactive with fiber and effectively improves dry and temporary wet strength, optimize fiber composition, improve retention, drainage and increase machine speed.

normal strength liner and is very sensitive to drainage.

Several Amphoteric DSR trials failed due to poor drainage and wet web sheet breaks. GPAM dosed in thick stock @ 10-15 kg/t meets the strength target and maintains good runnability.

Multi-function booster case: One Thailand Gypsum board with high Amphoteric DSR demand and porosity downgrades. It showed a very narrow operation window to find strength, drainage and board quality balances.

Liquid, pump and go.

You can find the stability study at different temperatures in Figure 3.

Product Property

FennoBond 3300LS

Appearance

Clear liquid

pH

3.0-4.0

Ionicity

Cationic

Viscosity (23°C)

15-30 mpa.s

Solids

10.5-11.5 %

Shelf life (25°C)

120 days

Figure 2: GPAM properties

Figure 4: Flow chart of Gypsum board machine Kemira proposed GPAM to break through current limitations, achieved big cost savings and commercialized this application for 2 years.

4 kg/t GPAM, dosed at thin stock (Figure 4), reduced existing Amphoteric DSR from 30 kg/t to 20 kg/t, increased 20 m/min machine speed, and less downgrade by high porosity value.

Figure 3: New generation stability improvement Best Practice 1: Strength or Multi-Function Booster for Containerboard Amphoteric Dry Strength Resin is the most popular dry strength chemistry in APAC, solid 15-20 percent, dosing point at thick stock, dosage from 5 kg/t to 30 kg/t based on burst, RCT, CMT target and furnish qualities. However, most Amphoteric DSR showed negative impact to drainage at higher dosage levels.

GPAM applies either as a replacement of existing strength chemistry or multi-function boosters in certain conditions.

Strength case: One Indonesia 3 ply machine produces

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Figure 5: Value calculator Based on the value calculation (Figure 5), 3.3 EUR/t GPAM cost, contributed to 12.6 EUR/t dry strength chemical savings, and 8.2 EUR/t more capacity generation by better drainage and less downgrades.

GPAM is flexible to apply in containerboard, big commercialized volume applied on either liner or corrugated medium to contribute a bigger operation window, more tolerance to materials or system variations and more productivity (runnability, speed, downgrades).

T•E•C•H T•A•L•K

Best Practice 2: Drainage and Runnability Booster to Virgin Paper or Board One Chinese art board machine uses Kemira GPAM for several years as a drainage booster. It is one of the biggest art boards in the world with 3000-4000 t/d capacity, NBKP, LBKP, BCTMP furnish, up to 25 percent ash content and 3 layers of coating.

Customers rely on GPAM to achieve strength targets at varied furnish qualities. GPAM also contributed to retention, drainage, dusting reduction and PAE boosting.

Detailed wet end info in Figure 7.

Both PAE and GPAM are with high cationic charge, anionic booster introduced to make sure the system is not over charged.

Existing retention system: Dry PAM 120 ppm + Emulsion PAM 120 ppm + Silica sol 3.5 kg/t and another 5 kg/t GPAM into thin stock to maintain its 1400+ m/min machine speed.

Wet end conditions shown in Figure 6. Relatively high conductivity than Average fine paper machines due to integrated pulp production.

Figure 6: Wet end conditions of art board machine

GPAM helps this giant machine to run at high speed and good runnability without influencing formation.

Best Practice 3: Dry Strength and Temporary Wet Strength for Tissue One global well known tissue maker uses Kemira strength system fortowel grade tensile properties.

Strength target MD tensile = 5,500 gf., CD tensile = 5,000 gf., CD wet tensile = 1,000 gf.

Kemira applied a triple components system for best cost efficiency.

•

Wet strength: FennoStrength PA21 (PAE) = 5-7 kg/t

•

Dry and temporary wet strength: FennoBond 3300LS (GPAM) = 20-40 kg/t depends on furnish

•

Anionic strength booster: FennoBond 85E = 5-10 kg/t

Figure 7: Tissue wet end conditions

Summary Market driven: Over 80 percent new machines startup belong to containerboard during 2020-2025 in APAC, there is no doubt that strength, drainage and runnability will be major targets and concerns. GPAM has proved to be a flexible and good choice to adapt to these applications.

Product availability: Kemira spent many years to develop Glyoxalated Polyacrylamide (GPAM) products and know how. The new generation GPAM with much improved shelf life would cover the needs from the whole APAC Countries.

Application development: With more challenges from raw materials shortage and variation, less water consumption and other sustainability requests, paper makers need solutions to open up existing limitations and maintain good productivity. Supported by the last 5-10 years of field practices, GPAM is applied in a smarter way and finds the right position to help as multi-function boosters.

Future of GPAM: Following the market and long-term needs, Kemira is under GPAM volumes expansion in APAC and onsite GPAM technology development for big consumers of strength and/or drainage.

By Tianxing Wen, Business Development & Application Development Manager, Southeast Asia, Kemira

Paper Excellence Secures Fiber Supply Vital to Restart of its Prince Albert Pulp Mill

N•E•W•S

Paper Excellence, headquartered in British Columbia, is a diversified manufacturer of pulp and specialty, printing, writing, and packaging papers.

September 9, 2021

P

aper Excellence has announced that its Prince Albert facility has been granted a softwood fiber allocation of 1,033,564 cubic meters per year by the provincial government.

The Prince Albert team also continues to meet with key Indigenous partners and businesses who will form our supply chains to discuss shared opportunities around the mill’s fibre supply and other aspects of its operation. 

Prince Albert facility

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D•I•G•I•T•A•L•I•S•A•T•I•O•N

ABB:

Implementing a Holistic and Robust Cybersecurity Approach

“ABB's approach has been to create a common, modular, and scalable infrastructure and then develop Industry 4.0 solutions within this architecture.”

A

Mr. Pravin K Singh, Associate Sales Director, Pulp & Paper (Process Industries Division), ABB India Ltd.

BB is a leading global technology company that energises the transformation of industries to a ch i e ve m o re p ro d u c t i v i t y. T h e solutions provided by ABB enable customers to reap the benefits of Industry 4.0 including cutting-edge robotics and digitalisation technologies, helping the country become a resilient high-tech manufacturing economy in the world. As a pioneer of quality control systems' scanning technology, ABB provides data analytics to papermakers, showing detailed product quality in real time.

In an interaction with Paper Mart, Mr. Pravin K Singh, Associate Sales Director, Pulp & Paper (Process Industries Division), ABB India Ltd. talks about the implementation of

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Industry 4.0 by the pulp & paper industry and the contribution of ABB in this regard.

Paper Mart: How according to you, has the implementation of Industry 4.0 has grown over the years? Do you think that the pulp & paper industry is ready to adapt to this evolving industrial revolution?

Pravin K Singh: The global pandemic has been an inf luential catalyst in forcing a traditionally hands-on industry to embrace digital faster than anticipated, creating a swing in the way mills operate and opening more opportunities for remote support and services and most notably commissioning.

This shift could become the silver lining of the pandemic. According to a recent

D•I•G•I•T•A•L•I•S•A•T•I•O•N

The examples of performance services include Paper Machine Drives Performance that provides online performance monitoring and predictive alerts; Sheet Break Performance that provides advanced warnings, fast root cause analysis and ideal operating parameters; and a suite of Virtual Measurements.

McKinsey & Co study, digitalisation, automation, and AI have the potential to deliver additional global economic activity of around USD 13 trillion by 2030, which we believe will be fuelled by data that forms the foundation of sustainable results.

However, data is only as good as the strategy behind it, including the collection and validation methods used. The mills should look for digital providers whose solutions are grounded in the real world of shop f loor operations, who know the industry as well as digital to provide real, long-lasting value. This will help make the data-driven applications more accurate and useful in optimising the pulp and paper process.

PM: What would be the impact on production efficiency and ROI with the implementation of Industry 4.0 technologies in the manufacturing process?

PKS: Digital solutions that leverage not just technologies, but also data, automation and process expertise have the biggest potential to make an impact. Also, ROI can quickly be achieved. For example, we have found with our recently released Paper Quality Performance, the improvements in reduced rejects alone would cover the cost of the subscription 1-5x over. In terms of efficiency, a lot of our solutions focus on making on-spec paper at less cost, such as Strength Virtual Measurements which give insight into the strength during the papermaking process to proactively make adjustments to keep targets costeffectively in spec.

PM: How does 'ABB Ability' enable paper mills to optimize their operations and increase profitability?

PKS: For organisations operating in the pulp and paper industry, collaborative efforts will accelerate digitalisation within their internal vertical value chain, as well as with their horizontal partners along the supply chain. This in turn will fuel i n n o v a t i o n , i m p r o ve c u s t o m e r interaction, and increase operational eff iciency. All our Performance Services are built on the ABB Ability™ platform: our unified, cross-industry digital platform — extending from device to edge to cloud.

These services include a broad range of pulp and paper-specific solutions focused on equipment availability, production output, product quality, and cost to produce. The examples of performance services include Paper Machine Drives Performance that provides online performance monitoring and predictive alerts; Sheet Break Performance that provides advanced warnings, fast root cause analysis and ideal operating parameters; and a suite of Virtual Measurements that use machine and process inputs to provide continuous online calculations more frequently than lab measurements.

These are only a few examples of ABB Ability Performance Services, which have been developed for both paper and pulp mills based on customer needs.

PM: Cybersecurity is an increasingly important requirement for Industry 4.0. In what ways does ABB address it?

PKS: A cyber security breach in pulp, paper, packaging, or tissue mill can bring production to a halt, leading to serious financial losses. It can also cause harm to workers, equipment, and the environment, destruction of data, and much more. And with the increase in Ransomware attacks, which have underscored that any industry that is sensitive to downtime is an appealing target to criminal organisations, increasing focus on cybersecurity should be a bigger priority. ABB recommends a defense-in-depth a p p r o a c h . We h a v e a d d r e s s e d cybersecurity at multiple levels. ABB has designed security into its solutions as well as created a security team to test and verify the security design of the solutions. ABB experts work together with customer teams to create a secure IT/OT infrastructure including leveraging outbound communication utilising a minimal number of firewall ports. Data is encrypted both in transit and at rest. Single sign-on user authentication along with limiting access to only what is needed based on authorization level. Overall, ABB implements a holistic and robust cybersecurity approach.

PM: Due to COVID resultant lockdowns, the pulp and paper industry recently shifted its focus on automation & remote commissioning — how does your solution simplify their operations?

PKS: Even prior to the pandemic, ABB has offered solutions that expedite remedy such as our previously mentioned ABB Ability™ Performance Services suite. These remote-enabled, software-assisted services use the Collaborative Operations service delivery model to connect mills to technology, analytics and expertise.

Together customers and ABB can troubleshoot and enable predictive maintenance actions to improve runnability and the reliability of drives performance.

From a project delivery side, we have also been agile at meeting needs in these

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D•I•G•I•T•A•L•I•S•A•T•I•O•N

(BGPPL), in Ballarpur, India saw successful remote commissioning of the Induction XP Plus Profiler system on PM3... We've also completed large-scale remote commissioning of winder drives, upgrading and commissioning PM5 installations at ITC's Paperboards and Specialty Papers Division.

pandemic conditions. Take for example two critical projects that were recently completed through remote commissioning. Bilt Graphic Paper Products Limited (BGPPL), in Ballarpur, India saw the One is the successful remote commissioning of the Induction XP Plus Profiler system on PM3, marking the

first time that an ABB CD control engineer has provided remote commissioning support for an upgrade of this kind. The modernization project was successfully and seamlessly delivered due to the world-class domain expertise of the team. We've also completed largescale remote commissioning of winder

DGTR Advocates Charging up to USD 542 MT Anti-Dumping Duty on Decor Paper Imports

drives, upgrading and commissioning PM5 installations at ITC's Paperboards and Specialty Papers Division mill in south-central India.

PM: What are your short-term and long-term plans — specific to the pulp & paper industry? What is the future of Industry 4.0 - smart manufacturing, and automation in the Indian pulp & paper industry?

PKS: ABB's approach has been to create a common, modular, and scalable infrastructure and then develop Industry 4.0 solutions within this architecture. The result has been the creation of a wide range of impactful solutions that are both scalable and cost-effective ranging from a single solution to an enterprise-wide approach. Going forward, ABB will be heavily engaged in smart factory concepts and autonomous operation.

N•E•W•S

As per the notification issued by DGTR — ITC Limited has also filed an application seeking initiation of anti-dumping investigation concerning imports of Decor Paper, originating in or exported from China.

October 1, 2021

T

he commerce ministry's fair trade watchdog Directorate General of Trade Remedies (DGTR) has recommended anti-dumping duty on decor paper imports from China. The anti-dumping investigation was initiated by the authority based on a complaint filed by ITC Ltd—the company that accounts for close to 80 percent of the domestic production of decor paper, a key material used by the decorative industry.

The final findings of DGTR—notified on September 28—stated that the domestic industry has suffered material injury due to anti-dumping. "The examination of subject imports and the performance of the domestic industry clearly shows that the volume of the subject imports has increased in absolute terms despite the significant capacity addition by the domestic industry. The imports are suppressing the prices of the domestic industry. The profitability parameters of the domestic industry have shown negative growth over the injury period (April 2016 - March 2020)", the report read.

The DGTR report also pointed out that non-imposition of the anti-dumping duty will adversely and materially impact the indigenous production—while the imposition of the duty will not materially impact the consumers or the downstream industry or the public at large. "On the basis of the information

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Decor Paper

provided by the interested parties and the investigation conducted, the authority is of the considered view that the imposition of the anti-dumping duty will not be against the public interest", the authority said. Depending on the Chinese importer, the duty range suggested by the authority is between USD 110 per MT to USD 542 MT of decor paper.

Of the 24,227 MT of decor paper India produces, 70 percent to 80 percent comes from ITC Ltd., Pudumjee Paper Products Ltd. and Shree Krishna Paper Mills & Industries Ltd. are the other domestic manufacturers of the product. n

I•N•D•U•S•T•R•Y W•A•T•C•H

Proklean Technologies:

Making Pro-Environment Speciality Chemicals “The product range of speciality chemicals is grounded on Green Chemistry to enhance cooking, pulp bleaching and reducing odour.”

I

ncreasing environmental concerns combined with their high cost of implementation, paper mills in India are constantly looking for green alternatives. While the chemical manufacturers have made significant progress with speciality chemicals to improve processes, there has been a pressing demand to make the industry more sustainable.

The development of eco-friendly speciality chemicals has further boosted the overall market growth of speciality chemicals industry. The speciality chemical manufacturers are implementing sustainable solutions, which include bio-alternatives and the use of energy-efficient separation methods.

Proklean Technologies with its range of products based on probiotics & biobased technology has broken new grounds by contributing to sustainability in paper and pulp processing without compromising on

Management Team cost or performance. The range of speciality bio-chemicals help in reducing the use of bleaching and delignification chemicals, cut down the generation of sulphides/mercaptans at cooking, thereby resulting in lower emissions, while also enhancing the profitability.

The products have delivered significant performance in multiple leading paper mills across the country including ITC, TNPL, Centur y and many more established mills in India.

Product portfolio for pulp & paper industry The products for the pulp & paper industry applications, sold under the brand name of ProCharta, are first-ofits-kind in the industry and find applications in cooking, delignification, and bleaching (oxidative and reduction) areas.

ProCharta products offer significant cost benefits to the user as they reduce the use of auxiliary chemicals. While the mechanical strength properties are

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I•N•D•U•S•T•R•Y W•A•T•C•H seen to improve due to the reduced use of chemicals, the effluent load is also seen to be lower.

The key features of ProCharta ProCharta is a first-of-its-kind technology product for application in the pulp & paper industry. It ensures reduced consumption of bleaching chemicals up to 30 percent and odour in the mill and in the final paper. Thus, it saves costs due to reduced use of chemicals. There is no change required in the process conditions and it can be applied at broad pH and temperature range.

ProCharta formulations are non-toxic and readily biodegradable and they are enzyme-based products. They can be stored at ambient temperatures up to 50°C and have one-year shelf life.

Further, they enable reduction of effluent load.

Experienced R&D Team Odour Control Typically odour is caused by volatile compounds of sulphur and nitrogen.

Chemistry behind the ProCharta technology

There are two mechanisms of odour reduction by ProCharta products:

Bleaching Enhancement

1. The biochemicals present in the formulation have the ability to react with the volatile organic compounds and convert them to non-odour causing soluble compounds and hence reduce odour

Metal ions of magensium, copper and iron form complexes with peroxide and tend to decompose the same and impair the bleaching performance. In order to optimise the performance of hydrogen peroxide, it is necessary to deactivate these metal ions through chelation or other processes. It is well known that bio-chemicals produced by probiotics have high antioxidant ability and are known to chelate magnesium/copper/iron ions due to the physiological chelators that exist in the intracellular cell-free extract of probiotics.

2. Two microbe species present in product, which are resistant to high temperatures, are also capable of using sulphur and nitrogen as their energy source and hence consume the same, thereby reducing the generation of odour causing volatile compounds.

The overall results produced by

Well equipped microbiology lab

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Proklean formulations is due to a combination of the above two mechanisms.

The formulations developed for application at cooking stage are e s s e n t i a l l y b i o d e g ra d a b l e b i o surfactants which are free of a n t h ra q u i n o n e . T h e s u r f a c t a n t character enables better penetration of cooking liquor which helps in dissolving lignin and other derivatives. This results in lowering the kappa number without degradation of f i b e r, t h e re b y i m p rov i n g y i e l d marginally.

Currently, there are six products introduced for the pulp & paper industry including ProCook – a cook aid for pulp mills; ProEnviro – odour controller for pulp mills; ProSolve+ – odour controller for Kraft paper;

State-of-the-art infrastructure facility

I•N•D•U•S•T•R•Y W•A•T•C•H

The team that is committed to sustainability ProWhite – delignif ication and bleaching enhancer; ProBleach – bleaching booster for recycled paper; and ProRB – bleaching enhancer for reductive bleaching.

These products are in regular commercial use in many large paper mills in India. All products are REACHcompliant and FDA-certified.

Established in 2012, Proklean Technologies Pvt. Ltd. has harnessed the power of probiotics to develop a range of bio-chemicals that are high performing, non-toxic and readily biodegradable. These products replace some of the toxic and hazardous chemicals used in various industries including the pulp & paper sector and

Coal Crunch in Uttar Pradesh May Force Paper Mills to Shutdown

reduce pollution in the process. An ISO 9001:2015, ISO 14001 and OHSAS 18001 certified company — Proklean is recognized as an APAC 25 company by C l e a n t e c h G r o u p. It i s a m o n g Biochemical Engineering Award finalists of the prestigious IChemE Global Awards for three successive years. n

N•E•W•S

On an average, the capacity of a paper mill in UP is 250 tonnes of paper per day which requires one rake of coal in a month. One rake of coal comprises 58 railway wagons carrying anywhere between 5,700 to 4,000 tonnes of coal.

September 10, 2021

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ccording to the media reports — the coal ministry's decision to prioritise the supply of coal for thermal power plants is likely to affect Uttar Pradesh's 35 paper mills that have coal-based power generation plants.

Based out of Bijnor, Muzaffarnagar, and Meerut regions — these paper mills account for almost 80 percent of Uttar Pradesh's concentration. These paper mills that have annual revenue close to INR 10,000 crore may have to shut down within the next two weeks due to acute shortage of coal.

Taking note of the situation, the Indian Paper Manufacturer Association (IPMA) has written to the secretary of the Ministry of Coal, stating that Northern Coalfields (a subsidiary of Coal India) has stopped supplying coal rakes to non-regulated sector customers and has diverted all rail traffic to thermal power plants for the past few days.

IPMA further addressed that these units generate their own

Paper Mill

electricity to run the plant, and that the coal stock at most of these plants is at very low level. If the coal rakes are not transported immediately, the paper mills will be forced to shut down, resulting in significant losses. n

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E•N•E•R•G•Y C•O•N•S•E•R•V•A•T•I•O•N

Danfoss Drives Technology Leading Energy Efficiency in the Paper Industry

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Author: Mr. Sujeeth Pai, Director of Sales and Service, Danfoss Drives India

oday, paper is manufactured largely by automated processes, right from the procurement of raw material to packaging. The main steps in the manufacturing of pulp and paper are raw material preparation and handling, pulp manufacturing, pulp washing and screening, chemical recovery, bleaching, stock preparation, and papermaking. It is a well-known fact that such processes expend large amounts of energy and water to attain the finished product. As the industry is poised to grow by 1.2 percent by 2030, the energy needs would only increase. It is therefore imperative for this energy-intensive industry with high water consumption levels to effectively reduce waste in a bid to reduce operational expenses and remain competitive as well as create a positive impact on the environment. The industry must also look at sustainable forms of energy to power its factories of the future.

Given that, the paper and pulp industry is highly automated, consuming large amounts of energy, every ounce of energy conserved is a step towards a greener future. Efficient ways of converting raw material to the finished product help in the reduction of carbon footprint. To repeatedly achieve high precision paper quality and finish, the paper mill demands high-tech control solutions to optimise the total cost of operations (TCO). By controlling the speed of pumps and fans to exactly meet and not exceed requirements, significant energy savings can be achieved in the paper machinery.

Sophisticated machine control enables improving process control by facilitating the collection of measurement and supervision information. Danfoss solutions deliver a precise and rapid control response, flexible integration to control the

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E•N•E•R•G•Y C•O•N•S•E•R•V•A•T•I•O•N system, and robust and accurate motor control. It enhances efficiency, reduces water consumption and operating costs, for controlling pumps, fans, and conveyors at the various mill sections, ranging from the pulp station with pulp dryer to stock preparation, and from pulp digestion and water treatment plants to paper finishing.

Continuous web control and winders are some of the most demanding applications in the pulp and paper industry.

Accurate torque control prevents the paper and wrapping material from crinkling. The AC drives must be capable of extremely accurate torque and speed control over a wide range, so torque resolution must be sufficiently high for these heavy industry applications. Manufacturers can achieve more rigorous winder control and that essential neat finish with the label in the correct place, with Danfoss solutions that reliably match the torque range and resolution required. Our solutions enable more precise operation of the unwind wrapping stations as well as positioning of the rolls used for centering and moving the paper rolls, which play an essential role.

A key part of the efficiency nexus is the reuse of resources and energy. The paper industry can tap into this process by embracing circular thinking pioneered by Danfoss. Circular

thinking in the paper and pulp industry context involves the use of production waste for heating purposes and trying to achieve zero liquid discharge (ZLD). While production waste is not something that can be controlled to a great extent, the reuse of freshwater is something that can be beneficial to both, the industry, and the environment. Waste heat from the HVAC systems can also be used to heat water in the creation of steam, which is an essential part of the paper-making process. These factors underscore the reasons for the effective reuse of resources......

Another method currently being evaluated is the recycling of old paper since the recycling process would conserve more energy than producing new paper from scratch. This is a welcome step given that this industry consumes a lot of raw material in its production process.

The Indian paper industry is in the beginning stages of a major transformation, with key players investing in upgrading facilities and capturing market share. To ensure the success of machine design or retrofit in the pulp or paper plant, Danfoss expertise in system control and control system override, dimensioning of drives, commissioning, switchgear knowhow, and overall project management, can play an integral role. n

Vapi Paper Mills Grapple with Coal Shortage

N•E•W•S

Vapi Industries Association has decided to make representations to the Central and state governments for smooth supply of coal to save the struggling paper mills.

October 21, 2021

A

round five paper mills at Vapi in the state of Gujarat have been temporarily closed their operations in the past one month due to coal crisis, impacting thousands of workers.

Amid warning of coal shortage — Vapi Industries Association has decided to make representations to the Central and state governments for smooth supply of coal to save the struggling paper mills in the region.

According to a leading daily — Mr. Sunil Agarwal, President, Gujarat Paper Mill Association stated that the electricity rates have gone up, putting a strain on the sector. If the supply of lignite coal is not streamlined, more units may shut in the coming days. Over a thousand people have lost jobs as of now… Production has also been reduced.”

There are around 100 kraft paper mills in Gujarat, of which 40 are located in Vapi GIDC. These paper mills consume around 60,000 metric tonnes of coal per month in the boiler to generate steam used to dry the wet paper. However, coal has been in short supply since September 2021, affecting production at paper mills.

According to the media report —the yearly turnover of the paper mills in Vapi GIDC is around INR 10,000 crore with a production of 2 lakh tonnes. Paper mills use coal imported from

Image source: Unsplash

Indonesia, while some use local lignite coal and some use a mixture of both. Indonesian coal has high Gross Calorific Value.

China recently started procuring coal from Indonesia after which supply to India got affected. The supply of lignite coal is not sufficient to fill the shortage.

Mr. Sunil Agarwal further added that the cost of imported coal has gone up from INR 5,000 per tonne a month ago to INR 15,000 now, Agrawal said it may jump over INR 20,000 per tonne. n

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D•E•H•U•M•I•D•I•F•I•E•R•S

Why We Need to Control the Moisture Content of Paper across Various Processes

P

aper Industry is one of the high priority industries having a bearing on socio-economic development globally. In India, the industry plays a vital role in overall industrial growth and is one of the fastest-growing industries. The paper industry in India consists of small, medium and large-sized paper mills manufacturing different grades of paper as per market needs. In order to obtain a good end product, the pulp & paper industry goes through multiple processes. The quality and characteristics of paper are the flagships of any manufacturer. If the quality of the paper is excellent, it leads to high revenue along with satisfied customers. But achieving the desired end product with unmatched quality is an

Author: Mr. Dinesh Gupta, Director, Bry-Air (Asia)Pvt. Ltd.

112 | www.papermart.in / August-September, 2021

arduous task. The key to success is optimal climate control in the production and storage stage. Pulp and paper manufacturing is a cumbersome process involving a lot of critical steps, factors such as high temperatures, high humidity, and constant water ingress are particularly challenging and can adversely impact productivity.

To define, paper coating is a method in which the paper is coated with a specific compound or polymer such as kaolinite, calcium carbonate or bentonite, to impart desired characteristics in the paper which enhances the quality of performance and printability. However, high solids and viscosity are needed to obtain a good printability and uniform coating layer.

Paper is naturally hygroscopic, making

D•E•H•U•M•I•D•I•F•I•E•R•S

it dimensionally unstable and vulnerable to temperature and humidity changes. Hence, it is quite important to maintain optimal air quality and humidity levels should be controlled.

It's one of the critical parameters to ensure smooth and efficient operations.

Once produced and reeled, the paper can be exposed to ambient conditions at the end of the paper machine for a considerable period of time. When the desired level is maintained throughout the manufacturing process, the moisture in the paper maintains not only the flexibility of the product but also leads to stable production and packing. Low humidity in the slitting area will cause moisture losses to occur; these losses will take place very quickly.

The paper sheds most of its moisture during the manufacturing process; it tends to retain moisture, particularly along the edges, during packaging and storage.

The other prevalent factor which needs to be given equal importance while manufacturing is the corrosive gases.

In the pulp & paper industry, there are different chambers associated to develop the products, such as DCS rooms, recovery boiler control rooms, pulp milk control rooms, fiber line control rooms, evaporated line control

rooms, and others. These control rooms get exposed to a wide variety of corrosive chemicals like chlorine, sulphides, hypochlorite and several other similar corrosive substances as products react at various stages while processing the pulp. The control room equipment is to be protected to achieve optimum reliability and productivity of the paper and pulp processing as high eminent chemicals and gases such as hydrogen sulphide, sulphur dioxide, carbon monoxide can bring the server in control rooms to a halt.

The protection of such rooms should be carried out by providing cleaned pressurised air; it is advisable to provide air leakage ports, again at the room ceiling level. By doing this, the MCC room shall not only be protected from corrosion but also enough air would be thrown out of the room to extract the generated heat.

When it comes to controlling the humid environment, the ambient conditions/production environment plays a major role in maintaining the humid situation along with the weather conditions. While the weather conditions are unpredictable, a minor deviation in the environmental conditions can lead to a high level of humidity. Bry-Air Dehumidifier can lower the moisture content of the

surrounding air in the manufacturing, packaging, and storage areas to the desired level and help upgrade the quality of the paper in terms of its performance and producing the final product.

Gas Phase Filtration System is the most ideal and cost-effective system to deal with any issue of corrosion in various control rooms. It is the key to airborne molecular gaseous and particulate contamination removal. Bry-Air Gas Phase Filtration Systems (GPF) Systems provides an optimum solution for efficient removal of air-borne contaminants causing corrosion, bad odour and harmful gases from the atmosphere. The systems are designed keeping in view various existing parameters such as contaminants presence and their concentration, airflow, space availability, and standard legacy systems in the contaminated atmosphere. The wide range of chemical media and macro-porous chemical filters are most suited for the efficient removal of almost all types of harmful contaminants.

Therefore, having gas phase filtration solutions, and desiccant dehumidifiers moisture control solutions are a blessing for the pulp & paper industry operators preventing them from the hassle of corrosion and abysmal product. n

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N•E•W•S

Valmet to Supply Coated Board Making and BCTMP Production Lines to One of its Customer in Asia The board machine order is included in Valmet's orders received of the third quarter 2021, and the BCTMP order was included in Valmet's orders received of the second quarter 2021.

Image source: Valmet

September 27, 2021

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almet will supply a coated board making line and a bleached chemi thermo mechanical pulp (BCTMP) production line with automation solutions, as well as spare parts and consumables packages to one of its customer in Asia.

The board making line with high productivity will produce very high-quality folding coated board grades.

The value of the orders will not be disclosed. However, a project of this size and scope is typically valued at around EUR 200 million.

“We have excellent relations with the customer at all levels resulting from several successful projects together during the past decades. We were able to meet customer's demand of a production line with high productivity and very high-quality products,” says Mika Ollikainen, Vice President, Sales and Marketing, Board and Paper Mills at Valmet.

Valmet's delivery will include mechanical pulping (BCTMP line), stock preparation and a high-speed coated board making line from headboxes to winders. The deliveries also include a wide range of automation solutions, comprehensive spare parts and consumables packages. n

Toscotec Starts up Turkey's Biggest Tissue Machine at Essel Kâğıt The new PM3 is manufacturing high quality tissue paper for the local market.

October 19, 2021

E

ssel Kâğıt has started up an AHEAD 2.2L tissue line supplied by Toscotec on a turnkey basis at its Osmaniye mill in Turkey. This is the fourth tissue machine that Toscotec fired up in a period of only three weeks in four different countries in Europe and Asia.

Featuring a net trim width of 5,700 mm and a production capacity of 270 t/d, this AHEAD 2.2L line is Turkey's biggest and most productive tissue machine. It features a fully hydraulic TT Headbox-MLT with dilution control, TT NextPress shoe press technology, a third generation TT SYD with optimized geome-

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try for increased heat transfer efficiency, and gas-fired TT Hoods with multiple stages of thermal energy recovery and designed for cogeneration upgrade.

The turnkey supply includes the complete stock preparation system, Toscotec's patented Short Approach Flow TT SAF®, electrification and controls, and dust and mist removal systems. The production line also includes two OPTIMA slitter rewinders with tension and nip control and automatic shaft puller for top winding efficiency. A full service package completes the turnkey supply: mill engineering, erection supervision, commissioning, training, start-up, and Toscotec's YES Connect-Vision AR system for effective on-remote service.

N•E•W•S Ahmet Temuroglu, Project Manager of Essel Selüloz ve Kâğit Sanayi Tic. A.Ş., says, “We are very satisfied with the outcome of this investment operation. Toscotec demonstrated their ability to manage and successfully complete a turnkey project on a tight schedule. They kept their focus on our common goal and showed great flexibility in solving various issues and adjusting their schedule to meet our requirements. The new AHEAD machine is already operating at a good efficiency, we are confident we will soon fully reap the benefits of this advanced technology.”

Pier Paolo Brunazzi, Toscotec Project Manager, says, “We had a very productive cooperation with Essel, as we built a trustbased relationship since the beginning. They are now operating Toscotec's top-of-the-line tissue technology including our latest product innovations. We expect them to achieve both their production and tissue quality targets in a very short time.” n AHEAD 2.2L tissue line

SMI Coated Products and FLEXcon Company Announce Partnership in India Complementing SMI's existing offering, the addition of the new products will enable the companies to bring a comprehensive range of solutions. SMI presents a wide range of paper and filmic label stock solutions.

September 3, 2021

S

MI Coated Products Private Limited, a company providing label stock solutions, and FLEXcon Company, Inc., an innovator in adhesive coating and laminating, has announced their association to bring durable label stocks in India.

India-based SMI has attained a strong brand presence amongst the printers/converters and is regarded as one of the key players amongst the top label stock companies in the country.

To date, the company has presented the end-user market with a wide range of paper and filmic label stock solutions using acrylic and rubber-based hot melt adhesives.

With the partnership with FLEXcon, SMI is going to provide polyester and vinyl label stocks with high-performance adhesives ideal for harsh environment labeling. Initially, the company will present eight of FLEXcon's base films that are ULrecognized in addition to one robust overlaminate.

Complementing SMI's existing offering, the addition of the new products will enable the companies to bring a comprehensive range of solutions in the automotive, outdoor power equipment, power tool, appliance, and electronics markets.

John Forster, VP International Sales & Corporate Development, FLEXcon, commented, “This synergistic relationship will allow SMI and FLEXcon to jointly provide exceptional products into

SMI Coated Products

the Indian market without the challenges of time differential or cultural barrier.”

The new solutions will have selections from pre-established ranges - THERMLfilm® NEXgen™ and COMPUcal® EXCEL™ and FLEXcon's recently launched FLEXcon® NEXgen™. Since the offerings are UL-recognized, they can be seamlessly adaptable into a printer/converter's UL file, allowing them to support equipment OEMs. n

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N•E•W•S

CMPC Signs Letter of Intent With Valmet for Modernization of Guaíba Pulp Mill in Brazil Valmet and CMPC target to finalize the contract during October 2021.

September 20, 2021

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almet and CMPC have signed a letter of intent (LOI) for Valmet to deliver key technology for the BioCMPC project.

The target of the project is to increase the production capacity of the Guaíba pulp mill's line 2 from 1.5 million ADt/y (air dry tonnes per year) to 1.85 million ADt/y. The modernization is expected to start operation in the fourth quarter of 2023.

This expansion project, BioCMPC, targets both to increase the production capacity of the Guaíba mill and also improve the environmental performance with for example increased production of renewable electricity and minimized water usage in pulp production process.

Valmet's delivery for the Guaíba pulp mill line 2 modernization will include rebuild of the pulp drying, fiberline, evaporation and white liquor plant, a new recovery boiler and new ash treatment, extended distributed control system including advanced industrial internet features. The technology delivery is supported by spare parts packages. The upgraded line is optimized for high reliability and performance with low environmental impact.

The pulp drying line upgrade will increase the drying and baling capacity and performance with the same high operational safety requirements that always guide Valmet's projects.

The upgrade includes improvements to screening and drying, automatic tail threading and an additional baling line.

The fiberline upgrade includes cooking plant technology update, fiberline improvements in brown stock and post oxygen washing and a new additional bleaching stage. The upgrade gives flexibility to minimize water usage and effluent generation improving the fiberline sustainability and environmental KPIs. The white liquor plant upgrade includes capacity increase of the recaustisizing and lime kiln. The modernized lime kiln electrostatic precipitator (ESP) and lime mud disc filter will ensure low emissions.

The evaporation plant will be upgraded to process 2,000 t water per hour. The eight-effect design provides high steam economy and features robust and reliable Valmet Tubel design. Improved

CMPC Guaíba Pulp Mill in Brazil

condensate treatment will lower water consumption of the mill.

The new recovery boiler will have a design capacity of 1,900 tds/d (tonnes dry solids per day) and will feature several highpower features for low energy consumption and high steam generation. The delivery also includes electrostatic precipitators (ESP) tailored for recovery boiler conditions. The recovery boiler ash will be treated with Ash Leaching Duo technology offering easy operation and improved leaching efficiency to maximize cooking chemicals recovery.

The CMPC Guaíba mill has already been the benchmark of the industry as an odorless mill. The collection and handling of the mill's odorous gases is further improved with NCG upgrades across process islands.

The automation delivery includes Valmet DNA distribute control system, advanced process controls (APC) for selected process areas, analyzers and online measurements.

The delivery is supported with extensive Valmet Industrial Internet (VII) services package with onsite and remote expert support.

The VII services include Valmet Performance Center support, Data Discovery, Dynamic Center Line Advisor, Performance Monitoring tools and Operator Training Simulator. n

Toscotec Starts up New Turnkey Tissue Line at Cartiera Confalone in Italy The AHEAD 2.2 tissue line supplied by Toscotec to Cartiera Confalone on a turnkey basis has come online at their new mill in Montoro, Italy, and started producing sellable tissue from day one.

September 29, 2021

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he new AHEAD 2.2 tissue line is equipped with TT NextPress, TT SYD Steel Yankee Dryer, and gas-fired TT Hood designed with multiple stages of energy recovery. It has a

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sheet trim width of 2,850 mm, a design speed of 2,200 m/min and production capacity of over 35,000 tpy. The tissue line will produce toilet tissue, napkins and towels using 100% pre-dried virgin pulp and converting broke.

N•E•W•S The turnkey supply included the complete stock preparation, Toscotec's patented TT SAF® (Short Approach Flow) for superior energy efficiency, the complete electrical and control systems, including the DCS and the QCS, as well as the dust and mist removal systems. The scope also included the vacuum plant, an automatic vibration monitoring system installed on the AHEAD 2.2 line and the machine hall ventilation system.

Toscotec also supplied two OPTIMA 2200 slitter rewinders, equipped with tension, nip control systems, and dust removal systems. The service package included detailed mill engineering, plant and tissue machine erection, commissioning, training, and start-up assistance.

Toscotec's AHEAD 2.2 at Cartiera Confalone, Italy

Cartiera Confalone's new Montoro mill constitutes the biggest tissue investment in the south of Italy in over twenty years and it is equipped with leading-edge tissue technology. n

PaperOne Recycling Programs Highlight Commitment to Circularity at Dubai Expo 2020 APRIL Group's premium, flagship range — PaperOne™ also highlighted some of the latest additions to its product range at Dubai Expo 2020.

October 5, 2021

P

aperOne™, the leading premium paper brand, has announced details of new recycling programs that it is introducing across key markets in the Middle East and

Indonesia Pavilion

Southeast Asia, in line with its commitment to increased material efficiency and circularity.

PaperOne will collaborate with document disposal and recycling partners in Singapore, Malaysia, Indonesia and the United Arab Emirates to support the collection of paper waste for recycling under the theme 'Paper Once More!'

In Dubai, PaperOne has partnered with a local paper shredding company that provides secure document destruction and recycling services across the United Arab Emirates to pick up wastepaper from various business locations for recycling. The new recycling program was recently highlighted at the international Dubai Expo 2020.

Office with APRIL Circular Economy Bin

Collectively, PaperOne estimates that the 'Paper Once More!' collaboration will result in the recycling of approximately

www.papermart.in / August-September, 2021 | 117

N•E•W•S 20,000 tonnes of paper waste in the first full year of operation, with scope for further expansion. PaperOne has also committed to support the recycling of one ton of wastepaper for every ton that is purchased by customers in Singapore, Malaysia and Indonesia through official branded online channels.

Exported to more than 70 countries, PaperOne is the flagship brand of APRIL Group, one of the world's leading producers of pulp and paper, which has production operations in Indonesia.

Bey Soo Khiang, Chairman, APRIL Group, said: “Our regional 'Paper Once More!' wastepaper recycling programs are a major part of our commitment to becoming increasingly circular and more sustainable as a business. The future growth of our business depends on our ability to become more circular, productive and diversified in a way that is sustainable and benefits climate, nature and people”.

Last year, APRIL launched its APRIL2030 commitments and targets to guide the development of the company's operations over the coming decade, building on the foundations of its Sustainable

Forest Management Policy 2.0. The company's APRIL2030 commitments include targets to increase material efficiency and circularity to achieve 98 percent chemical recovery and 25 percent less process water usage per product tonne.

Wanyan Shaohua, Head of Paper Business, APRIL Group, said: “These recycling programs can also have a significant practical impact. In Malaysia, we're helping to collect over 2,000 metric tonnes of wastepaper for recycling purposes, with the use of five recycling trucks and 10 recycle bins. To put this into perspective, the height of 2,000 tonnes of wastepaper stacked together would be taller than the Petronas twin towers in Kuala Lumpur.”

PaperOne also highlighted some of the latest addition to its product range at Dubai Expo. PaperOne Script has been engineered for scholastic needs and is alkaline sized to meet ISO 9706 standards for archival quality. The PaperOne 75 GSM two-ream pack has been specially designed for e-commerce purposes and comes with a high-quality box, which protects the two reams of paper during delivery to the end consumer. n

Volga Pulp and Paper Mill Orders New OCC Line From ANDRITZ to Convert PM 6 ANDRITZ has received an order to convert paper machine from newsprint to packaging paper production for Volga Pulp and Paper Mill, Russia. The Start-up is scheduled for the spring of 2023.

September 21, 2021

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NDRITZ has received an order from Volga Pulp and Paper Mill in Balakhna, Nizhnij Novgorod Region, Russia, to supply a new OCC line as well as to convert its PM 6, a newsprint paper machine, to a packaging paper machine.

After the conversion, PM 6 will produce packaging paper from a unique mix of OCC and TMP fibers – a groundbreaking raw material composition for the production of packaging paper.

Volga Pulp and Paper Mill is currently producing packaging paper from 100 percent TMP fibers and has now opted for this innovative solution to save resources. The rebuilt PM 6 will have an annual production capacity of 140,000 tons and a design speed of up to 720 m/min, producing lightweight fluting and testliner in the range of 65–120 GSM. The rebuild includes the paper machine approach flow system, the forming, press and dryer sections, including the steam and condensate system, a new PrimeFilm film press, some of the paper machine drives, as well as the complete tail threading system and the slitter rewinder.

The new OCC line will process local OCC (Old Corrugated Containers) and feature a capacity of 400 bdmt/d. ANDRITZ will supply all of the main equipment, from bale receiving to the dump chest, including a FibreFlow Drum pulper (type FFD350EE), which is a complete pulping system in one unit. The new drum pulper will ensure superior accept quality thanks to the gentle pulping concept and efficient removal of coarse contaminants with minimum fiber loss. Furthermore, the drum

118 | www.papermart.in / August-September, 2021

ANDRITZ FibreFlow Drum pulper

pulping technology is a perfect match for the upcoming changes in raw material and for furnish with increasing reject content. The OCC line will be delivered with an extended scope, including fractionation, screening, cleaning, and pumps as well as automation and electrification equipment with a DCS from ANDRITZ. The ANDRITZ scope includes supervision of the mechanical installation work, commissioning, and start-up assistance.

In 2020, Volga Pulp and Paper Mill successfully started up a new TMP line supplied by ANDRITZ. This repeat order further strengthens the fruitful long-term relationship between the two companies. n

N•E•W•S

Essity Invests in World's First Tissue Machine Running on Geothermal Steam The production of tissue from geothermal steam is part of Essity's work to use less energy and achieve net zero emissions by 2050.

October 6, 2021

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ssity is investing in enhanced efficiency in the company´s site in Kawerau, New Zealand, including the world's first tissue machine running a fully geothermal steam drying process. Together with a reduction in pulp consumption, reduced waste and elimination of the burning of natural gas on the machine, the improvements will contribute to a reduction of carbon emissions by 23 percent from the Kawerau site.

Essity is proud to lead the industry for environmental and social sustainability performance across its operations in Australasia.

Improvements include sustainable packaging supporting the Australian National Packaging Targets, certified sustainable fiber sources, ethical supply chains, and reducing manufacturing waste and water use.

The investment of approximately AUD 15 million (approximately SEK 95 million) is partly funded through the

Tissue Paper Machine at Kawerau Site

Government Investment in Decarbonizing Industry (GIDI) Fund, administered by EECA (Energy Efficiency and Conservation Authority) in New Zealand. n

China's Zhejiang Forest United Paper Orders Key Board Machine Technology From Valmet The order is included in Valmet's orders received of the third quarter 2021. The value of the order will not be disclosed. However, a project of this size and scope is typically valued at around EUR 10 million.

October 7, 2021

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almet will supply key board machine technology to Zhejiang Forest United Paper in Taizhou in the province of Zhejiang in China. The key technology will be installed in a new containerboard machine (PM6). The start-up is scheduled for 2023.

Valmet's delivery will include four OptiFlo Foudrinier headboxes, an IntelliFormer top forming unit, four OptiCoat Roll coating heads with roll application and a large quantity of OptiDry Coat air dryer units. One of the air dryers is a completely new of its kind, OptiDry Coat double-pass, which combines three dryers in one compact unit, and gives high coating and printing quality, as well as optimized energyefficiency and runnability. The delivery will also include Valmet DNA machine control system for the coating section and spare parts and consumables packages.

6,300-mm-wide (wire) board machine will produce white lined

A completely new type of an air dryer, OptiDry Coat double-pass, will be delivered to Zhejiang Forest United Paper

chipboard grades with a basis weight range of 180-350 g/m2.

The mechanical design speed for the new parts will be 1,000 m/min and daily capacity over 1800 tonnes. n

www.papermart.in / August-September, 2021 | 119

N•E•W•S

Italy Achieves EU Paper Recycling Target 15 Years Early Italy's race on the circular economy continues. And it is getting better and better, so much so that the country is 15 years ahead of the European paper recycling targets.

October 27, 2021

I

taly has hit the target set by the European Union for paper and cardboard recycling 15 years early, as confirmed by Unirima — the association representing Italian firms in this sector.

As reported in a leading daily — in its 2021 report compiled with the Althesys business consulting agency, Unirima said that Italy recycled 87.3 percent of its paper and cardboard in 2020, already ahead of the 85 percent target set by the EU for 2035.

It said 600 facilities in Italy processed 6.8 million tonnes of waste paper last year, increasing the output of raw materials for paper production by 3.2 percent and meeting market demand. n

Paper Recycling

Smurfit Kappa Acquires a 600,000 Tonnes Containerboard Mill in Northern Italy Verzuolo mill owned by the Burgo Group is situated optimally close to SKG's Southern European corrugated facilities. This strengthens SKG's integrated operating model and it also supports the Group's sustainability ambitions.

October 12, 2021

S

murfit Kappa Group (SKG) has now completed the acquisition of Verzuolo at a price of around USD 416.12 million (EUR 360 million). The Verzuolo mill owned by the Burgo Group, is situated close to the port of Savona in the northwest of Italy. The PM9 machine was constructed in the year 2002 and was converted into a 600,000 tonne capacity recycled containerboard machine in 2019.

This mill is highly complementary to SKG's existing operations as it is strategically positioned close to the port of Savona. It is expected to deliver significant benefits for both the Group and its customer base. n

Image: Smurfit Kappa Group

Valmet Sets Up Pilot Facility at its Fiber Technology Center in Sundsvall, Sweden The new Pretreatment BioTrac Facility in Sundwall is quite flexible and can test different feedstocks and develop, verify, and optimise the pretreatment processes.

October 25, 2021

V

almet's new Pretreatment BioTrac pilot facility has started operations in at its Fiber Technology Center in Sundsvall, Sweden.

120 | www.papermart.in / August-September, 2021

With this investment in the new pilot facility, Valmet is primarily looking to strengthen its research and development capabilities in the field of biomass pretreatment and cater to the new market demands for bioenergy, biofuels, and biochemicals.

The facility provides piloting and laboratory services for

N•E•W•S Valmet's clientele. Further, it will also offer the opportunity to test different feedstocks and develop, verify, and optimise the pretreatment process for specific purposes.

The pilot facility's pretreatment system is flexible and can process many different raw materials. With the aim to enable several different process configurations including acid impregnation and several different reactor configurations like vertical and horizontal reactor systems. The process control is safeguarded by the Valmet DNA system.

The new Fiber Technology Center (FTC) of the leading global technology company is situated in the city of Sundsvall, Sweden. Sundsvall is 21st largest city in Sweden by population and the pulp & paper industry has an extensive presence. n

Valmet Fiber Technology Center in Sundsvall, Sweden (Image: Valmet)

ANDRITZ Successfully Starts up Pulp Production Equipment for Bracell's STAR Project Project STAR is one of the largest and most sustainable pulp mills in the world, operating with the highest environmental standards.

September 20, 2021

A

NDRITZ has successfully started up key production equipment for the first of two environmentally friendly hardwood pulp production lines supplied for Bracell's “STAR” project in Lençóis Paulista, São Paulo.

The second line is expected to be started up by the end of September 2021.

Project STAR features two flexible, environmentally friendly hardwood fiberlines for a capacity of 2.6 to 2.8 million tonnes/year of bleached kraft pulp or 1.5 million tonnes/year of dissolving pulp made from sustainably cultivated eucalyptus.

The ANDRITZ A-ConFlexTM continuous kraft and dissolving pulping technology enables flexibility in production of highquality dissolving pulp and kraft pulp. With this delivery, ANDRITZ once again confirms its position as the only technology supplier with solid references and experience in continuous cooking of dissolving pulp. With a capacity of 13,000 TPD, the ANDRITZ HERBTM recovery boiler is the largest in the world.

It will make the mill self-sufficient in energy supply and additionally produce around 180 megawatts of green energy for the Brazilian grid. This covers the energy consumption of about three million people in the region.

Bracell's STAR Project in Brazil

enhanced with state-of-the-art ANDRITZ IIoT Smart Woodyard solutions to ensure optimum chip quality,

Ÿ

two flexible fiberlines with DD-Washer technology,

Ÿ

the largest EvoDryTM Pulp Drying System in the world, with two energy-efficient pulp drying lines and equipped with the Metris DryQ smart pulp drying solution and Metris remote connection to ensure a fast start-up,

The ANDRITZ scope of supply includes:

Ÿ

an ANDRITZ HERB recovery boiler,

Ÿ

Ÿ

a non-condensable gas (NCG) treatment system. n

a complete, high-capacity wood processing plant,

www.papermart.in / August-September, 2021 | 121

N•E•W•S

Russia's Arkhbum Tissue Group Orders Tissue Production Line From Valmet The new tissue production line from Valmet is part of Arkhbum Tissue Group's development project aimed at reaching a total capacity of 210 thousand tonnes of high-quality tissue and towel products made from own pulp.

October 4, 2021

V

almet will supply a complete tissue production line including stock preparation, automation system and a Focus rewinder to Arkhbum Tissue Group LLC. The new Advantage DCT 200 tissue line will be installed at the company's mill in Vorsino industrial park, Kaluga region in Russia.

The start-up is planned for the first quarter of 2023.

The order is included in Valmet's orders received of the third quarter 2021. The value of the order will not be disclosed.

However, a project of this size and scope is typically valued at around EUR 20-40 million.

The new tissue machine TM2 will have a width of 5.6 m and a design speed of 2,000 m/min. It will add 70,000 tonnes a year of high-quality napkin, toilet, and towel grades to Arkhbum's current production. The raw material to be used in the tissue production will be virgin fiber from the owner's own pulp mill.

The new production line is optimized to save energy and to enhance the quality of the final product.

Valmet's scope of delivery will comprise of a complete tissue production line including stock preparation systems and a Valmet Advantage DCT 200 HS tissue machine. The machine will be equipped with an OptiFlo TIS II headbox, the Advantage ViscoNip press combined with Advantage ReDry and a steel Yankee dryer. It also features other Advantage tissue technol-

Valmet's Tissue Production Line

ogy including an AirCap Heli hood, WetDust dust system and a SoftReel, and complete clothing packages with Valmet Forming Fabric GMs, Valmet Press Felts STMs and Valmet Black Belt R ViscoNip belts. The stock preparation line will consist of OptiSlush pulpers, OptiFiner conical refiners, Valmet DX protection screens and OptiScreen machine screens. In addition, a Focus Reelite R25 ENS rewinder as well as a roll handling system will be installed.

Furthermore, the delivery will include a Valmet DNA Automation System with process controls, machine controls and drive controls. Valmet IQ Quality Control System (QCS) with IQ Fiber sensor, MD Controls and IQ Dilution profiler with CD Control ensure high end-product quality. n

Essity Begins Tissue Production From Alternative Fibers This new type of tissue paper is as soft, bright, and strong as traditional tissue paper.

September 30, 2021

H

ygiene and health company Essity has presented a breakthrough in sustainable tissue production and is beginning production based on pulp from wheat straw. The plant in Mannheim, Germany, is the first of its kind in Europe, and the first on a large-scale tissue production in the world.

Essity is the first company in the tissue industry to use these agricultural leftovers at industrial scale. About half of all straw worldwide remains unused. The straw used in this production is sourced in the region and is processed by Essity. With straw instead of wood-based virgin or recovered fibers as raw material, the process also requires less water and energy.

Essity has an exclusive licensing agreement for the technology, where the straw-based pulp will maintain the same quality as conventional wood-based pulp at a competitive cost. The straw pulp will initially be used in tissue products for the German

122 | www.papermart.in / August-September, 2021

Tissue Paper

consumer retail market under Essity's market-leading brand for household towels and toilet paper, Zewa. The products will contain about 30 percent straw-based pulp. n

N•E•W•S

WEPA Starts up New Tissue Line Supplied by Toscotec on a Turnkey Basis The new tissue line produces premium quality recycled hygiene paper primarily for the Away-from-Home market.

October 14, 2021

W

EPA and Toscotec started up an AHEAD 2.2S tissue machine at Piechowice mill in Poland. The new line is part of a full turnkey supply by Toscotec, starting from the bale handling system and bridge crane up to the parent roll handling system.

The AHEAD 2.2S machine has a sheet trim width of 2750 mm, a maximum operating speed of 2100 m/min, and a production capacity of over 36,000 t/y. It features Toscotec's shoe press of new generation TT NextPress, a third-generation-design TT SYD, gas-fired hoods with multiple stages of energy recovery, and an in-line shaft puller integrated in the pope reel section.

The turnkey included the complete stock preparation, Toscotec's patented TT SAF® (Short Approach Flow), the complete electrical and control systems, including DCS and QCS, and the dust and mist removal systems. The project also included the vacuum plant, air compressor station, bridge cranes, roll handling and hall ventilation systems. Toscotec provided a comprehensive service package with the detailed mill engineering, the plant and the machine erection, commissioning, start-up supervision and detailed training.

This is the fourth turnkey tissue project supplied by Toscotec

Toscotec's AHEAD 2.2S tissue machine at WEPA Piechowice mill in Poland

to the WEPA Group, following three previous turnkey operations at WEPA Lille (France) and WEPA Giershagen (Germany) both in 2015, and WEPA Piechowice in 2017. It is also the sixth complete tissue machine that Toscotec has supplied to the German group, including one line installed at WEPA Kriebstein, and one at WEPA Giershagen. Since 2006, Toscotec has also provided seven hood rebuilds to WEPA at five different mills in Germany and Italy, which improved the energy efficiency of the existing tissue lines by delivering a significant reduction of gas and power consumption and increase in machine run-ability. n

Shandong Huatai Paper Orders Voith to Rebuild PM 11 After the rebuild, the state-of-the-art machine will produce wood-free uncoated paper with significantly increased productivity.

September 2, 2021

O

ne of the world's largest newsprint producers Shandong Huatai Paper is going to rebuild and modernize PM 11 with the aim to progressively convert newsprint production to high-quality graphic paper. The papermaking company has selected Voith as the supplier for this project.

Following the rebuild, the annual production capacity of the line will reach 520,000 TPA at a design speed of 1,800 m/min. At present, Shandong Huatai Paper has an annual production capacity of 1.5 million TPA. The rebuilt production plant that is situated in the eastern Chinese province of Shandong, is scheduled to start up in 2023.

Further, the solutions ensure production that is sustainable by reducing the carbon footprint and decreasing water and fiber consumption. Additionally, a new MasterJet Pro G headbox is used, that will enhance paper quality in addition to achieving major savings in energy costs. Also, in order to attain higher throughput as well as optimum formation, Voith experts are upgrading the forming section similar to the DuoFormer concept.

Image: Voith

New ProRelease+ HighEnd boxes in the pre-dryer section guarantee improved web stability at high speeds.

Furthermore, a SpeedSizer AT with its smooth film application will ensure even and high-quality paper profiles. The efficient CombiDuoRun drying concept will be installed in the afterdryer section. The scope of the order also consists of new automation solutions designed to efficiently upgrade the existing control systems. n www.papermart.in / August-September, 2021 | 123

N•E•W•S

Metsä Fibre and Lehto to Build an Ecological Operating Office for Kemi Bioproduct Mill With an investment of around USD 1.9 billion, the Kemi bioproduct mill is the largest-ever investment in the history of the Finnish forest industry.

September 4, 2021

M

etsä Fibre, a subdivision of Metsä Group, and Lehto Group have signed an agreement to construct an ecological operating office from wood for the Kemi bioproduct mill in Finland.

Kerto® LVL wood products from Metsä Wood will be used in the construction. The upcoming office building will be an impressive, four-storey wooden structure, including the main control room for the bioproduct mill, office and social facilities.

The total area of the building will be 4,235 sq m. Presently, Lehto Group is also in the process of constructing a 40,000 sq m product warehouse for the bioproduct mill in the Ajos harbour in Kemi.

With a total investment of around ~USD 1.9 billion (EUR 1.6 billion), the Kemi bioproduct mill is the largest-ever investment

Image: Metsä

in the history of the Finnish forest industry. The new bioproduct mill will employ around 2,500 people in Finland. n

Metsä Board's Multimillion Investment to Increase Folding Boxboard Capacity in Sweden The investment in Husum mill, Sweden, is driven on the growing demand for sustainably produced packaging materials. AFRY has been selected for an engineering assignment for the said investment project aimed to increase the folding boxboard production capabilities.

October 8, 2021

M

etsä Board, a subdivision of Metsä Group, has partnered with AFRY for an engineering assignment aimed to increase their folding boxboard production capacity in Husum mill, Sweden.

As the consumers have become more aware of the environmental impact, the demand for wood-fiber-based products and packaging, such as folding boxboards has increased substantially. Metsä Board is a European leading producer of folding boxboards.

The company is now directing its efforts towards more sustainable production with increased production efficiency and environmental performance. Metsä Board's overall investment value is approximately USD 242.9 million (EUR 210 million).

The project will increase the capacity from 400,000 tonnes to

124 | www.papermart.in / August-September, 2021

Metsä Board – Husum mill, Sweden

600,000 tonnes. The full production capacity is expected to be attained by the end of 2025.

The engineering assignment includes detailed engineering of process, mechanical and piping, electrical, instrumental, automation, and HVAC as well as project planning services. n

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Event Calendar Pack Plus 9 - 11, December 2021 New Delhi, India www.packplus.in

Paperex 2022 9 - 12, January 2022 Greater Noida, India india.paperex-expo.com/Home

Tissue World Miami 16 - 18, March 2022 Miami, USA www.tissueworld.com

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* Due to COVID-19 event status could change. Please check with the organizers before visiting.

TAPPICon 2022 1 - 4, May 2022 Charlotte, NC USA www.tappicon.org

Paper Middle East 3 - 5, September 2022 Cairo, Egypt www.papermideast.com

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Paperex South India 2022 23 - 25, November 2022 Chennai, India southindia.paperex.in

Aug-Sep, 2021

Vol.: 22 / No.: 03

Editor & Publisher Parveen Kumar Jain – pkj@tulip3pmedia.in Associate Editor Geetika Jain – gjain@papermart.in Editorial Team Anurima Mondal – desk@tulip3pmedia.in Laique Khan – desk2@tulip3pmedia.in Soumya Ojha – desk3@tulip3pmedia.in Graphic Designer Ravi Thakur – ravithakur@tulip3pmedia.in Tajinder Singh – design2@tulip3pmedia.in Advertising & Marketing Puneet Dua – mktg@papermart.in Akansha Tiwari – mktg3@tulip3pmedia.in Priya Thapar – mktg2@tulip3pmedia.in Support Team Kushagra Mehrotra Sandeep Kumar Rahul Kumar admin@tulip3pmedia.in Chief Executive Officer Priyank Jain pj@tulip3pmedia.in Editorial & Publisher's Office : Paper Mart, Tulip 3P Media Pvt. Ltd. 218, Sanjay Nagar, Gulabi Bagh, New Delhi-110007, INDIA

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