APP Sustainability Report 2008-2009 - Asia Pulp and Paper

Sustainable Products
Sustainable Products
Ekamas Fortuna
Overview and Background
APP’s Ekamas Fortuna mill is located in Desa
Gampingan village, some 35 km south of
Malang in East Java, and was established
in 1984 on a 25-hectare scrubland site,
adjacent to the Les River. It was originally
constructed by a Malang-based cigaree
manufacturer to produce outer cartons for
use as delivery packaging for its products.
Inially the mill had one 2.5- metre-wide,
20,000 tonne/annum mul-vat board
machine, with a second 3.9 metre-wide twinwire
fourdrinier machine added in 1991.
The mill went into receivership in July 1993,
just as an expansion of the second machine
to more than 110,000 tonnes/annum was
being commissioned, and was purchased
from the administrators and become part of
the APP group of companies, in September
1994.
Subsequent upgrades of both paper
machines under APP’s ownership, and
expansion of the mill’s converng capacity
in 2001 has given Ekamas Fortuna a current
nominal producon capacity of about
175,000 tonnes/annum. Authorisaon is in
place for an expansion in capacity to 203,000
tonnes/annum.
The mill is the major employer in its locality.
Table 55 - Employment
2008 2009
Direct employees 1,044 1,141
Indirect employees 864 1,141
Statutory Obligaons:
Environmental Permits and
Compliance Reporng
The mill is regulated under a UKL / UPL
schedule authorised by the KLH (Indonesian
Environment Ministry) office for Malang
Kabupaten, and reports its operaonal,
environmental and socio-economic
performance to that office on semi-annually
and quarterly for waste.
The mill has current cerficaon of its ISO
14001:2004 Environmental Management
System (EMS), due for renewal in 2011. It
improved its rang in the PROPER appraisal
scheme operated by KLH from Red in 2008
to Blue minus in 2009. The improved rang
resulted from progressive clean-up of open
dumping and accumulaon of boiler plant fly
ash and boom ash through licensed third
Table 56 - Aggregated Mill Producon
pares, and the introducon of brick-making
from it. The mill received a license in 2009
to convert its fly ash and boom ash to
bricks and paving for internal and external
use. In addion, no penales were given to
Ekamas Fortuna for non-compliance with
environmental laws and regulaons in 2008
and 2009.
Paper Producon
Ekamas Fortuna’s packaging products
include corrugang medium, wrapping
papers, chipboard and kra liner. The
relavely small mill occupies a niche market,
selling its mainly “value” grade packaging
predominantly into the Indonesian domesc
market - largely on the island of Java - with
some 10 percent exported within Southeast
Asia. Other value-added products include
seamless and non-seamless cores / tubes,
shopping bags, paper cones and sheeted
paper. The mill’s products are 100 percent
post-consumer waste-based, with the
excepon of some of its kra wrapping
papers and kra liner, which have a
significant virgin unbleached sowood kra
pulp (NUKP) content.
Raw Material Inputs
Waste Paper
The mill’s principal raw material is postconsumer
wastepaper, which comprises
more than 95 percent of its fibre furnish.
This is obtained both within Indonesia and
by import from Singapore, the U.S. and
Europe. Mill broke levels, re-incorporated
into products, averaged 4 percent in both
years.
Purchased Pulp
Post-consumer waste inputs are augmented
with a much smaller quanty of imported
unbleached sowood kra pulp (NUKP) used
to improve the strength, and parcularly
the tear strength, of certain paper grades.
Consumpon in 2008 and 2009 was 5,074
tonnes and 9,309 tonnes, respecvely.
Ekamas Fortuna occasionally obtains small
quanes of low-grade bleached hardwood
kra pulp (LBKP) from Indah Kiat Perawang
Mill (29 tonnes in 2008), for use in specific
grades of plasterboard liner.
Starch and Process Chemicals
Raw and modified starches (oxidised on-site
using hydrogen peroxide – H 2
O 2
) play an
important role in enhancing the internal
and the surface strength properes of
most waste-based packaging papers. Hence
starch represents the most significant
non-fibre component of our raw material
inputs. Other important components of
our paper and board are sizing agents
that are used to regulate water and ink
penetraon, aluminium sulphate (“alum”)
that is required as part of the sizing process
(also for raw water treatment), and a range
of dyes, system cleaners, and drainage
and retenon aids. Fillers are rarely added
to packaging papers although they will
be present to a limited extent from the
wastepaper used. Total chemicals used
in 2008 and 2009 respecvely are 13,462
tonnes and 13,330 tonnes.
Table 57 - Raw material inputs
(tonnes) 2008 2009
Wastepaper - Local 83,993 87,915
Wastepaper - Imported 67,121 69,837
Energy
Thermal Energy Inputs
Locally-supplied (East Java) coal is used
to fire our 3 x 20 tonnes/hour chain grate
boilers and was the primary source of fuel at
Ekamas Fortuna in both years, providing 99.5
percent of thermal energy requirements in
2008 and 98.1 percent in 2009. In addion,
two marine fuel oil / heavy fuel oil boilers
are retained for stand-by use.
The amount of coal consumed during this
period increased by some 16 percent, from
46,125 tonnes in 2008 to 53,374 tonnes in
2009, with a mean caloric value of 6,050
Kcal/kg. Mill thermal energy input totalled
1,216,148 GJ in 2008, 1,413,662 GJ in 2009.
This equates to a 12 percent increase in
specific thermal energy consumpon from
8.14 to 9.16 GJ per AD tonne of paper.
Graphic 8 - Energy consumpon (%)
Electricity
Marine Diesel
Fuel
Coal
1.5 G Joule 1.7 G Joule
20.5
0.5
79
2008 2009
19
1
79
Energy Generaon and Efficiency
No electricity is generated on-site. The
amount of electricity consumed increased
from 86,511 MWh in 2008 to 93,882 MWh
in 2009. This gives a specific electrical energy
usage of 579 kWh/AD tonne and 608 kWh/
AD tonne for 2008 and 2009, respecvely.
The increases in both thermal and electrical
energy consumpon from 2008 to 2009
were due to an increased producon of highenergy
consumpon grades (chipboards,
core boards and kra liner grades). There
are no World Bank / IFC thermal and
electrical energy consumpon guidelines
for recovered fibre paper mills producing
corrugang medium and packaging papers.
Water
Water Usage
Raw water abstracon from the adjacent
Les River was 1,639,023 m 3 in 2008 and
2,117,243 m 3 in 2009. The mill’s permied
water abstracon limit is 2.24M m 3 /annum.
Measured wastewater discharges were
972,226 m 3 in 2008 and 1,226,050 m 3 in
2009. The discrepancies between incoming
and outgoing water volumes for both years
(41 percent and 42 percent, respecvely)
was predominantly due to evaporave losses
but, perhaps warrant further invesgaon.
(ADT) 2008 2009
Board 159,994 152,555
[EN 28]
[EN 1, EN 2, EN 3, EN 4, EN 8, EN 21]
56 APP 08/09 Sustainability Report
APP 08/09 Sustainability Report 57