Annual Report 2011 - Ballarpur Industries Limited

16
Unit: SFI
One of the major
achievements on the
Customer servicing side
during 2010–11 was
a 40 per cent drop in
customer complaints as
compared to 2009–10.
This is mainly due to
proactive steps taken
in maintaining quality
during production and
tight Quality Control
Systems across
processes.
Identified potential consumers for fly
ash generated from the coal boilers and
doubled the supply from 30 MT per day
(2009-10) to 60 MT per day (2010-11)
100 per cent utilization of waste acid
generated from Clo 2 Plant in bleaching
stage for pH control, which resulted in
improvement of effluent quality
As a green initiative, constructed five
rain water collection pits for rain water
harvesting.
ballarpur industries limited | annual report 2010–11
unit: ashti
In 2010-11, the Unit produced 53,299 MT
of paper, which was 1,691 MT lower than the
output in 2009-10. This production has been
lower on account of higher downtime and
adverse product mix. After commissioning
of the satellite plant of SMI at Ballarpur, the
Unit completely changed over to Precipitated
Calcium Carbonate (PCC) as filler, which has
helped in improving product quality as well as
cost reduction. Further, the Unit has replaced
the primary centri-cleaner pump to a higher
capacity one for improving the centri-cleaning
efficiency, which resulted in the improvement
of product quality. This, combined with
other quality improvement initiatives have
resulted in substantial reduction of customer
complaints by 65 per cent in 2010-11.
In the area of environment protection, the
Unit has successfully carried out retrofitting
and up-gradation of Electrostatic Precipitator
(ESP) to achieve suspended particulate
matter at 50 mg/NM 3 , which is much below
the statutory norms. The Unit has also been
able to reduce water consumption by 16 per
cent per MT of paper produced during the
year by improving the vacuum flume recycling
system and reuse of water in the process
which has finally reduced the effluent water
of the mill by 20 per cent per day thereby
improving the ETP discharge effluent quality.
The Unit catered to the retail business
by producing around 15,214 MT of paper
for various brands like Ten on Ten, Matrix
Premium Multi Purpose Paper (MMPP),
Matrix Premium Digital Paper (MPDP)
and P3 segment. A testimony to the Unit’s
improvement in product quality is the success
achieved in exporting paper to 20 countries
across the globe, where the products are
competing with international brands and
meet high quality norms.
In addition to the existing A-4 packing line,
a second A-4 line has also been shifted from
Unit Sewa and re-commissioned at this Unit,
enabling it to increase the volume of inside
cutting and packing of A-4 Copy paper to
43,242 MT in 2010-11, which is 6,088 MT
higher than the previous year.
As part of management commitment
towards systems implementation, in 2010-
11, the Unit obtained recertification of QMS
ISO 9001:2008, EMS ISO 14001:2004 and
ISO 18001:2007 certification of OHSAS. The
Unit is also Forest Stewardship Council FSC-
COC certified.
unit: sFi
During 2010-11, paper production from the
Unit was 131,909 MTPA, which is about 12
per cent lower than 2009-10. Lower paper
production was mainly due to an annual
shut-down in September and October, 2010.
The annual shut-down is normally once in
18 months for inspection and servicing of
pressure vessels as per the requirements of
Department of Safety and Health (DOSH),
Malaysia. There was an overrun of 9 days
in this annual shut-down, mainly due to
delay in implementation of DCS system on
paper machines. The other factor which
led to lower production was the start up and
commissioning of the new MCO2 plant in
Pulp Mill tie in shut in June 2011. Out of the
total paper production of the Unit, 40,631
MTPA was exported. The bleached pulp
production was 100,067 MTPA, which was
12 per cent lower than 2009-10.
On the raw material front, the mix has been
changed to increase consumption of Acacia
Mangium against Mixed Tropical Hardwood
to improve paper formation and reduce
production cost. SFI paper grades have
moved up in positioning in terms of quality
amongst its regional competitors. Another
notable parallel occurrence is the significant
drop in paper dirt count.
One of the major achievements on the
Customer servicing side during 2010–11 was
a 40 per cent drop in customer complaints as
compared to 2009–10. This is mainly due to
proactive steps taken in maintaining quality
during production and tight Quality Control
Systems across processes.
As regards plantation activities, the major
change from past practices has been to
directly employ labour rather than relying
entirely on contractors. By the end of 2010-
11, more than 200 Indonesian nationals were
employed on land preparation and planting
activities. This was necessary as contractors
were unable to meet the plantation targets.
The plan is to increase the numbers of
such workers to more than 500 in 2011-12.
Consequently, plantation coverage increased
from 2,200 hectares (ha) in 2009-10 to 4,100