About us The Confederation of Indian Industry (CII) works to create and The Centre is housed in a Green Building which received the sustain an environment conducive to the growth of industry in prestigious LEED (Leadership in Energy and Environmental Best Practices Manual India, partnering industry and government alike through Design) Platinum Rating in 2003. This was the first Platinum advisory and consultative processes. rated Green Building outside of U.S.A and the third in the world. The Centre was inaugurated by H.E Dr A P J Abdul Kalam, the CII is a non-government, not-for-profit, industry led and then President of India, on July 14, 2004. Pulp & Paper industry industry managed organisation, playing a proactive role in India's development process. Founded over 117 years ago, it is Volume 5 India's premier business association, with a direct membership of over 6600 organisations from the private as well as public sectors, including SMEs and MNCs, and an indirect membership of over 90,000 companies from around 250 national and regional sectoral associations. With 63 offices including 10 Centres of Excellence in India, and 7 overseas offices in Australia, China, France, Singapore, South Africa, UK, and USA, as well as institutional partnerships with About IPMA 223 counterpart organisations in 90 countries, CII serves as a reference point for Indian industry and the international Indian Paper Manufacturers Association (IPMA) has emerged as business community. a national level organisation and is an apex Association provides a broad based common platform to project Industry's view and CII – Sohrabji Godrej Green Business Centre (CII – Godrej GBC) is to articulate its strategy to cater to the growing need and global one of the 10 Centres of Excellences of the Confederation of vision of the Paper Industry. Large Paper Mills from private and Indian Industry (CII). public sector with a product mix of all varieties of Paper (Writing, Printing, Packaging, Speciality, Paper boards and CII-Sohrabji Godrej Green Business Centre offers advisory Newsprint) located in all regions and using conventional fibre services to the industry in the areas of Green buildings, energy such as wood and bamboo and also unconventional raw efficiency, water management, environmental management, materials like bagasse, recycled paper, etc. Comprise the renewable energy, Green business incubation and climate Membership of IPMA in broad spectrum. The Association is change activities. registered with the Registrar of Societies, Government of NCT of Delhi. The Centre sensitises key stakeholders to embrace Green practices and facilitates market transformation, paving way for IPMA strives to promote, protect and improve trade, commerce India to become one of the global leaders in Green businesses and Industry in general, with a focus on Industry connected with by 2015. Paper in particular. For further details, please contact: Mahesh Puranam Survey No 64, Kothaguda Near HITEC City, Hyderabad - 500 084 [email protected] Tel: +91 40 44185 101 +91 40 44185146 Fax: +91 40 23112837 www.greenbusinesscentre.com Best Practices Manual Pulp & Paper industry Volume 5 1 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Disclaimer © 2012, All rights reserved. No part of this publication may be reproduced, stored in retrieval system, or transmitted, in any form or by any means electronic, mechanical, photocopying, recording or otherwise, without the prior written permission from CII- Sohrabji Godrej Green Business Centre, Hyderabad. While every care has been taken in compiling this Manual, neither CII-Godrej-GBC nor Indian Paper Manufactures Association (IPMA) accepts any claim for compensation, if any entry is wrong, abbreviated, omitted or inserted incorrectly either as to the wording space or position in the manual. The Manual is only an attempt to create awareness on Energy, Water and Environmental management and sharing of best practices being adopted in Indian Paper industry and the international cleaner production technologies. Published by Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre, Survey # 64, Kothaguda Post, R R District, Hyderabad –500 032 India. 2 Best Practices Manual - Pulp & Paper Industry The Indian paperForeword industry is growing at a fast clip and, given that the Indian economy is expected to continue to grow at the present rate (or higher) for the next 20 years with a corresponding increase in literacy rate and affluence, the demand for paper will only continue to grow. The Indian paper industry, with a long legacy of over a century and a mix of large and small firms using old and new technology, is building up capacity to cater to this increasing demand. A large number of the units are embracing newer, more energy efficient technologies and ecologically sustainable practices, and are showing increasing awareness of the environmental problems facing the world today. CII – Sohrabji Godrej Green Business Centre has the vision of making India a global leader in green business by 2015, and one of its focus sectors is the Indian pulp and paper sector. As a means of achieving this vision, the Centre facilitates industries in adopting best available technologies and best operating practices, thus enabling them to become world class energy efficient units. To take this idea forward, the Indian consortium of CII – Sohrabji Godrej Green Business Centre and Indian Paper Manufacturers Association (IPMA) are presently involved in a two year project with IVL and Innventia, both Swedish research institutes with extensive experience in the paper sector, to identify the needs of the Indian pulp and paper sector and to develop a roadmap for implementation of clean technologies. This activity is funded by the Swedish International Development Agency (SIDA). The key objectives of the project are: Transfer and exchange of know-how and experiences, increase awareness and capacity to protect the environment and manage climate change; thus contribute towards socially, economically and environmentally sustainable development in India. Broaden and deepen bilateral collaboration between Sweden and India for improving the environment performance by introduction of cleaner technologies in Indian pulp and paper sector The expected outcomes of the project are knowledge sharing/ transfer in pulp and paper sector and introduction of new cleaner production technologies best suited to the Indian context. The annual event ‘Papertech’ and this manual on Cleaner Production Technologies & Best practices are also efforts that enable stakeholders to interact with others and learn from them. I would like to express my gratitude to all the CEOs of the various pulp & paper mills in the country for their contributions, guidance and support in shaping this initiative. I would also like to thank Mr Pradeep Dhobale, Executive Director, ITC Ltd for his continued support for all our initiatives related to making Indian Pulp & paper Industry world class. My congratulations to Mr K S Kasi Viswanathan, Chairman, Paper Tech 2012 and all the members of the core working group for their efforts and contributions. I am sure that this manual would go a long way in facilitating quicker adoption of best practices in Indian pulp and paper industry. Dr Naushad Forbes Chairman Energy Efficiency Council, CII-Godrej GBC & Director, Forbes Marshall 3 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Preface The year 2011 was an eventful year for the Indian pulp and paper Industry. Many large capacity, high speed, state of the art paper machines have been commissioned during this year. Quality of paper manufactured in the country has jumped. The utilization of secondary fiber has also shown a significant jump. With increasing pressures on availability and cost of input materials , cost of manufacturing paper has become the real focal point. Energy is simply not available and it’s price is going up by the day. This will continue. Needles to mention, same is the case with water. Stakeholders are becoming more environmentally conscious and the corporate social responsibility & “Environment friendliness” of a company is increasingly used as a measure to assess a company’s performance. The industry has proactively reacted to these challenges, addressing the Energy and Environmental concerns at all levels of manufacturing. Meantime, Government of India has also provided an impetus for Energy efficiency by introducing the Perform, Achieve and Trade (PAT) scheme under the “National Mission for Enhanced Energy Efficiency (NMEEE)”. The PAT scheme has been notified to the Designated Consumers (DCs) on March 30th, 2012. Under the scheme, the DCs in the pulp and paper sector are required to reduce their specific energy consumption within a specified time frame. Companies meeting the Target SEC will be benefitted, while companies not meeting will be penalized. However the scheme provides a great opportunity for the paper sector to explore new ideas and technologies to reduce energy , become green and also reduce their cost of production. When CII – Sohrabji Godrej Green Business Centre, on it’s part, embarked upon its journey to “Make Indian Pulp and Paper Industry World Class” in the year 2008, it was our vision that the Indian paper industry should improve it’s performance particularly relating to Energy, Environment and water and be a leader for the world. Over the last four years, this journey has been extremely rewarding and the Indian paper industry has certainly gone from strength to strength. For us, developing a “Best Practices Manual” for the sector every year, has been a small way to help stakeholders to continue with their good work in this initiative. Earlier versions received encouraging response by the sector, buoyed by which, we present to you this latest edition of the best practices manual. In this manual, apart from the best practices identified from various plants in India by a core expert group, we have also included a few cleaner production technologies identified from Sweden. This manual has been prepared with extreme care, and the case studies presented here have good potential for replication and adoption.