Annual Report 2011 - Ballarpur Industries Limited

14
There has been a
significant increase
in capacity of Unit
Ballarpur with the
installation of a new
state of art paper
machine, which was
commissioned by
Allimand, France with
an installed capacity of
165,000 MTPA.
OPERATIONS
BILT’s consolidated paper manufacturing
operations span across six production Units,
five of which are in India and one in Malaysia.
The Indian Units are located at Ballarpur
(Maharashtra), Bhigwan (Maharashtra),
Shree Gopal (Haryana), Sewa (Odisha)
and Ashti (Maharashtra). The Malaysian
Unit, SFI is in the State of Sabah. The rayon
grade pulp manufacturing Unit is located at
Kamalapuram (Andhra Pradesh).
The details of operational developments
across the different Units are given below.
ballarpur industries limited | annual report 2010–11
unit: ballarpur
During 2010-11, Unit Ballarpur produced
230,752 MT of paper. There has been
a significant increase in capacity of Unit
Ballarpur with the installation of a new state of
art paper machine, which was commissioned
by Allimand, France with an installed capacity
of 165,000 MTPA. During 2010-11, this new
machine produced 118,134 MT of Paper. The
state of art machine and finishing section has
enhanced quality, provided better packaging
for customers and reduced manpower
engagement.
On the product development front, the Unit
has successfully manufactured new shades
in various products, namely BILT Magna
Print, Wisdom Print, MICR Cheque Paper,
Maplitho and Extensible Sack Kraft Paper
(ESKP) to meet customer requirements, in
domestic as well as export markets.
At the back-end, bleached pulp production
was 115,329 MTPA. Enhanced operational
efficiencies resulted in increased pulp
production with uniform brightness and
increased viscosity. The Pulp mill operations
have been further optimised with change in
the raw material mix of wood and bamboo,
which has resulted in enhanced performance
of the paper machines in terms of quality of
paper produced.
Environment management and resource
conservation continued to be a key focus
area. Water conservation is a key area where
the mill has reduced consumption by over
30 per cent per MT of paper produced.
This was achieved by adopting the 3-R
(Reduce-Reuse-Recycle) methodology,
which is much lower than the national
standard. While the Unit has added additional
equipment for improving quality of paper
which has increased electrical load, power
consumption was reduced by 5 per cent per
MT of paper produced. This was achieved
through implementation of various energy
saving innovations across the pulp and paper
manufacturing process. During the year,
Non-Condensable Gas Incineration system
was commissioned for control of bad odour
from the plant.
As a part of technology adoption for energy
and environmental sustainability, the existing
pulp mill is being replaced with a modernized
pulp mill for which civil and erection work is in
progress. The modernized pulp mill will have
all advanced energy and resource efficient
control systems.
achievements and awards
Unit Ballarpur is certified for the FSC COC
and Control Wood certificate by the Forest
Stewardship Council.
Unit Ballarpur has a certified Integrated
Management System of ISO 9001:2008,
ISO 14001:2004 and OHSAS
18001:2007.
Unit Ballarpur also secured the
Environmental Best Practices Award 2011
from CII GBC Hyderabad for innovative
environmental best practices.
unit: bhigwan
During 2010-11, Bhigwan PM-1 line
produced 142,646 MT of Coated Paper and
Coated Boards - an increase of 9,412 MT over
2009-10. The newly commissioned state of
the art PM-2 paper manufacturing line, which
started commercial production in March
2009 produced 140,670 MT of Coated Paper
during 2010-11, an increase of 24,921 MT
over 2009-10. The total production of the Unit
was 283,316 MTPA, an increase of 34,333
MTPA over 2009-10.
The Unit successfully developed several
new products during the year. This includes
art paper for digital printing and gravure
printing, art card suitable for injection
moulding painting process (paint shade
cards job) and new shade development
(High whiteness) in printed circuit board. All
the new products were well received by the
market.
Resource conservation continued to be
a key focus area for the Unit. Innovative
process changes, optimization of coating
formulations and wet end chemical usage
has helped in reducing usage of chemicals
and fibre consumption, which has offset the
impact of rising input prices to a large extent.
A number of energy conservation measures
have resulted in significant reduction in
power consumption in the existing paper
machine by over 9.2 per cent per MT of paper
produced in 2010-11.Water consumption in