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Volume 30 No. 3 July - September 2018

Pawan Agarwal Country Editor
President
B. V. Ramarao, USA
Ved Krishna G. H. (Goeff) Covey (Australia)
Vice President Mahendra Doshi (USA)
B. P. Thapliyal Pekka Niku (Finland)
Editor-in-Chief Samuel Schabel, Germany
M. K. Goyal Sujit Banerjee (USA)
Secretary General
Editorial Advisers

Anil Naithani
D. K. Singhal
Ganesh Bhadti
N. K. Bhardwaj
P. K. Bajpai
Raghvendra Hebbar

Articles are Pre Reviewed by the Editorial Board

ISSN - 0379-5462
Quarterly Journal of Indian Pulp and Paper Technical Association
Registered with the Registrar of Newspaper for India (Government of India)

under Periodical Regn. No. 26516/73

Published by IPPTA, Saharanpur
Facts and views expressed in articles in the Journal are those of the authors and the Association

assumes no responsibility. Material published in IPPTA Journal is not to be reproduced
with written permission from IPPTA

Articles for Publication, advertisement, correspondence, membership dues and change of address should be addressed to :
INDIAN PULP AND PAPER TECHNICAL ASSOCIATION (IPPTA)

CPPRI Campus, Paper Mill Road, Near Himmat Nagar, Saharanpur -247001 (U.P.) India
Tel : 0132- 2714081 M: 08979443353, 09719002076

E-mail : [email protected], [email protected], [email protected], [email protected]
Website : www.ippta.co

Designed and Printed at :
Adinant Graphix, DA 142, Salt lake, Kolkata - 700 064
Ph. : 033 4004 3761 / 4602 0201 E-mail : [email protected]

IPPTA - The Official International Journal // Volume 30 No. 3 // July - September 2018
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Editor-in- Chief 3
Presidential Address 4
Vice Presidential Address 6
Secretary General Address 7
Interview 8
Mr Paul Sharma - Sharma Paper Pvt. Ltd.
Meet the Key Note Speaker 10
Organising Committee
Chairman Message 11
About Hyderabad 12
Calendar of Events 24
Glimpses of Muzaffarnagar Seminar 25
Corporate Social Responsibility 42
Annual Sponsorship Details 48

ADVANCED ANALYTICS FOR OPTIMIZATION OF STAGE-WISE ISO 49 123 INCREASING PRODUCTIVITY THROUGH AUTOMATION
BRIGHTNESS GAIN IN KRAFT PULP BLEACHING Suraj Mohapatra

Srikar Turumella, Katuri Joseph, Sivashankar Subramanian, 54 128 NALCO WATER, AN ECOLAB COMPANY USES AUTOMATION AND ON-
Kunisetty Rambabu, Nikhil Jain, K.Sriapathi LINE REAL TIME MONITORING TO HELP ON PRODUCTIVITY, WATER
AND ENERGY CONSERVATION
ADVANCED ANALYTICS IMPROVE MILL PERFORMANCE AND RELIABILITY
Jari Almi, Samuli Lehtonen Sundar R, Padmanabhan, Mohan

AUTOMATION IN PAPERMILL FINISHING HOUSE 57
K. Sudhakar, K. Sivarama Krishnan 131 OPTIMIZED AUTOMATION AND CENTRALIZED MILL DATA
ACQUISITION TECHNIQUES FOR PAPER MAKING
AUTOMATION SOLUTIONS IN PROCESS, PRODUCTIVITY, AND QUALITY IN
PULP & PAPER INDUSTRY FOR SUSTAINABLE PAPER MAKING 69 Muralidhar Ekambaram
Barathi G
143 OPTIVISION CENTERLINE - SOLUTION NOTE
BUSINESS PROCESS AUTOMATION FOR PROCESS, PRODUCTIVITY, Niranjan Rao
QUALITY & MARKETING OPTIMIZATION AT TNPL BOARD MACHINE
73
FINISHING HOUSE 145 PAPER MILL AUTOMATION FOR CUSTOMER SATISFACTION AND
S.Nandagopal, V.Thiruppathy, P.Prince Tholkappian, S.Senthil PROFIT MAXIMIZATION – CASE STUDIES OF PAPER MILLS IN INDIA

Dr. V. Barla

COLLECTION AND INCINERATION OF NON CONDENSABLE GASES (NCG) 81 148 PAPERMAKING 4.0 BY VOITH
THROUGH AUTOMATION By VOITH

T. Harischandra Prasad, N.V.S.M Krishna 92 160 REDUCTION IN COST OF POOR QUALITY (COPQ) DUE TO BLOTCHES
CONTINUOUS IMPROVEMENTS IN PAPER MANUFACTURING IN PAPER MACHINE USING ADVANCED ANALYTICS

AUTOMATION AT TNPL Vini Sehgal, Somnath Roy, Sanjay Dhabarde, V. Murali

R. Rajalingam, R. Murugavel Ananth, K. Kumaresan 164 THE CONCEPTION OF INDUSTRY 4.0 IN THE ENVIRONMENT OF

IMPROVING PAPERMAKING WITH INTEGRATED WEB MONITORING AND 101 PULP AND PAPER COMPANIES IN INDIA
WEB INSPECTION CAMERA SYSTEMS
P K Suri, Balveer Mishra, S. P Singh, U.P Tripathy

Kari Hilden, Cloin Bridge 169 YOKOGAWA’S SYNAPTIC BUSINESS AUTOMATION - AN APPROACH

INCEPTION OF IN-HOUSE AUTOMATION A MARCH 108 TO THE OPREX PROFIT DRIVEN OPERATION INCLUDING IIOT AND
TOWARDS INDUSTRY 4.0 DIGITAL TRANSFORMATION

KBS Krishna, Srikanth Ganala, Shaik Junaid Anil Dutt

IPPTA - The Official International Journal // Volume 30 No. 3 // July - September 2018

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Message of Editor-in-Chief

Indian paper industry is witnessing technological upgradations and has upgraded process technology
coupled with advanced automation & control. The developments have shown the result of enhanced
productivity, quality of products, effective resource utilization, improved efficiency, asset management
and better environmental management. It is now common to see DCS, QCS, MCS, commonly referred
as third industrial revolution, in operation in majority of the mills in India. Some progressive Indian mills
have started to explore the benefits of Fourth Generation automation initiatives by experimentation
of mill wide virtual networking, artificial intelligence for simulation of processes and decision making
etc. and are gearing themselves for adoption of these solutions in near future.

I welcome the initiative of IPPTA for organizing the Zonal Seminar on Automation for Process, Asset,
Productivity, Quality & Marketing Optimization at Hyderabad from 23-24 November, 2018. The venue
as well as the theme of the seminar is very appropriate and relevant as Hyderabad is one of the major
IT hub in the country. Microsoft and Google have their India Headquarters in Hyderabad. The city
also houses offices/workstations of other companies like Yahoo, Oracle, Nokia, Dell, AMD, Accenture,
Amazon and so on.

There is a need for pulp and paper mills to keep abreast with the latest technological advancement.
However, the relevance of shaping the current technological trends towards the futuristic technologies
related to automation is also crucial. Automation is regarded as the basic platform for the industry to
move ahead towards industry of future, i.e., Industry 4.0, therefore the topic of the seminar assumes its
significance. This seminar would thus provide a useful window to the mills in this respect. I welcome
the initiative of IPPTA for trying to outreach the maximum pulp and paper mills by organizing such
seminars for the benefit of the industry. This will help not only to ensure increased participation of
the pulp and paper mills but also will help in creating awareness and facilitating knowledge up
gradation of the technical manpower working in the industry.

I am pleased to note that the articles and presentation received for this seminar reflect various
technological developments / innovations in the area of automation for process, asset, productivity,
quality and marketing optimization. I hope the deliberations during the conference will be useful to
the participants to takeaway innovative ideas and concepts for implementation in their mills and
make their mills future ready.

With best wishes for the success of the Seminar !

Jai Hind !

B. P. Thapliyal
Editor-in-Chief - IPPTA

IPPTA - The Official International Journal // Volume 30 No. 3 // July - September 2018
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IPPTA - The Official International Journal // Volume 30 No. 3 // July - September 2018
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“It is heartening to see that the demand has taken a northward trend in all varieties of
paper and Board in the last few months. There have been several factor for the same - ban
on import of mixed waste paper in China, spurt in demand of pulp, appreciation of dollar
against rupee and increase in demand of newsprint (forcing many Indian paper mills to
switch over to newsprint). Whatever may be the reason, the paper mills have improved
their financials, including the top and bottom lines. The improved balance sheets of the
mills means that there will be more potential of investments in near future. The investment
scenario in various fields like pulp mill, machine, recovery and power plants looks very
bright. This new wave of investment after almost a decade will have focus on not only
generating quality machines and equipment but also on employing energy efficient and
environment friendly technology. It has also been felt that the modern plants would need
to focus a great deal on automation and digitisation in order to take the operational
efficiency to a new level. The technical parameters are interlinked with the financial and
commercial parameters through mills’ ERP systems. This is a new development which
takes the financial calculations to the technical key persons though an integrated digital
system, called Internet of Things. IoT has become a possibility in various operations in
paper mills of India today.

In the above background, IPPTA is organising a first-of-it’s-kind seminar at Hyderabad
to cover all the aspects of automation and digitisation. I am sure paper mills will take
immense benefits out of the deliberations and presentations on various technologies
related to this path-breaking concept in this seminar.

I am thankful to the organising and program committees for their untiring efforts to make
this program a success.”

Best wishes,

Pawan Agarwal

President - IPPTA

IPPTA - The Official International Journal // Volume 30 No. 3 // July - September 2018
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Vice President’s Message

strategic locations and they were operated on a
GPS based app. Through this customers could get
assured 30 mins delivery for cement whenever they
wanted. We need to learn from the world around
us. There is so much happening and each domain
can have people who are doing things better than
us. The key is to seek, understand and adapt.

Dear Friends, Finding the right implementor and defining the
scope is so important and we, at our company have
Technology, when implemented well, can bring made so many errors in this domain. We have to
benefits that are beyond ROI. ensure that the vendor has the right amount of
experience, is motivated and aligned to our vision. I
The question really is of understanding our real find that we tend to focus too much on cost and end
needs, finding the right technology and implementor, up with partners with inadequate understanding or
implementing well and then ensuring results. accountability. We have to become clearer about our
own needs and have a very clear scope document.
Our business needs are the key determinator of It is well worth involving an expert at this stage
technological adaptation and the same needs from our side so that we can learn about our own
to be understood. We need to define our plans needs and define clear milestones. Deliverables
and strategy well. Technology for its own sake will need to be defined through business needs and
not bring any real dividends. Business needs are not just technical (which is what the vendors
fundamentally defined by our customers and the usually want to limit themselves to). When we were
markets we are trying to serve. One fundamental implementing SAP one of the key deliverables was
question for any decision needs to become about a clear formatted online P&L available on call. We
the impact on our market and customer and that are still waiting for it after 3 years!!
would also define priority. We have to see how we
are trying to differentiate ourselves, technology It is easier to monitor results when we know clearly
usage will be different if we wish to become an on what we are looking for and commercials for
time delivery company vs if we are striving to be the the project need to be aligned to the same. The
lowest cost or the best quality. The greatest risk is to monitoring has to go and implementation needs
try being all things at the same time. to become part of the process where a certain
resultant is being provided on a regular basis. We
wanted to implement an online contribution per
hour on every machine and the way we did it was
to have a monitor on every machine that displays
the same all the time. The operator knows when
he is in he green and when he goes into the red.
Simple and straightforward.

Technology is so important that we have a separate
IT Committee on our board. We all need to have
clear roadmaps for our companies.

Once we are clear about what our targets are we In the end, we need to keep it as simple as we can. If it
need to start seeking to plug in technology and cant be understood it is not worth implementing.

today’s world offers a plethora of options. One The topic chosen for Hyderabad is of utmost
recommendation is to never limit ourselves to our importance and I look forward to the deliberations
industry. An example of this is Cemex, one of the ahead.
biggest cement industries in the world that prides
itself on its technology usage. It was looking to be Best wishes,

the best at delivery and decided to learn the same Ved Krishna
from Über. It ended up placing loaded trucks at Vice President - IPPTA

IPPTA - The Official International Journal // Volume 30 No. 3 // July - September 2018

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From the Desk of Secretary General

Conference after conference IPPTA continues to scale newer heights. We conceived a fresh perception and held a conference
over workshop at Muzaffarnagar, a Tier 2 City in the month of August this year. To begin with, an attendance of 125 was
perceived to be pretty high by all optimistic expectations and with a low initial registration it was presumed that the
estimates were indeed very optimistic. However, as the conference date came nearer, the number of participants swelled
to 200+ and finally ended in the vicinity of 300 delegates. It was quite tough for a small team to manage the show which
ended well, thanks to the great effort put in by the local team lead by Mr Pankaj Agarwal. IPPTA on its part ordered extra
bags which were delivered after the conference to the remaining delegates. It is true that such responses make us happy,
but this last minute registration creates havoc with the basic arrangements made for the conference. It is therefore my
humble request to all the members to help us by registering in advance.

IPPTA has just concluded its KNOWLEDGE TRIP-II to South Korea. The trip was organised in collaboration with UNIDO
Korea with a helping hand by CPPRI. We are thankful to Dr Bipin Thapliyal – Director CPPRI and Ms Anuradha V Janbade
Scientist EII –CPPRI for their help in organizing the trip for us. The response to the trip was amazing. We had envisaged
25 heads in original group, but the response was overwhelmingly huge as we received request for more than 45 heads
and could finally manage to accommodate 30 heads only. The visit covered all grades of paper manufacturing viz, Writing
printing, Kraft, fluting media, tissue, board and news print. Delegates could also witness few large conversion plants for
baby diapers, hygiene and box making facilities. Our special thanks to Ms Hye Young Lee of UNIDO for the meticulous
planning and execution.

Hyderabad conference being held on 23rd and 24th November 2018 has again evoked a very high response. Against
the requisite 12 papers that can be presented we have received 26 papers. Besides, majority of the papers have excellent
contents and are of very high quality. The Technical committee had a hard time to carry forward quite a few papers. We
would like to thank all the authors for their contribution.

The proceedings of the seminar and arrangements are being personally looked after by Mr. Sanjay Singh and Mr Nagahari
with on ground support of Mr Basab Ghosh alongwith a large organising and programme committee members. Apart from
12 technical papers two panel discussions have been arranged which shall be chaired by galaxy of speakers. We expect an
excellent show and I would like to thank delegates in advance for their kind presence.

M K Goyal

Secretary General, IPPTA

IPPTA - The Official International Journal // Volume 30 No. 3 // July - September 2018
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PAUL SHARMA, MD
Sharma Papers Pvt Ltd

Kraft Paper Industry on a steady
growth curve

Growth to be spurred by urbanisation, rising population and Chinese
government’s decision to ban import of waste paper

The Indian kraft paper industry is passing through rather interesting phase with
demand growing and prices improving. The Chinese government’s decision to
ban import of waste paper into the country owing to environmental concerns has
served as an impetus to the domestic kraft paper industry, which has been witnessing a
steady growth, thanks to the rising urbanisation and increasing population in the country.
In an exclusive interaction with IPPTA, Mr Paul Sharma, MD, Sharma Papers Ltd, spoke
about the way forward for the kraft paper industry in India and the company’s plans.

IPPTA - The Official International Journal // Volume 30 No. 3 // July - September 2018
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What is the demand for kraft paper in What is the kind of technological upgradation
India? How is it growing? What are the and R&D practices being undertaken in
key attributes to the growth? the Kraft paper industry to keep in tune with
changing demands?
At present approximate demand of Kraft Paper is
5lakhMT per month andthe growth rate is 8-9 per Not much R & D activity is happening in the
cent. The growth has been fairly steady and the Industry but technology up gradation is taking
key attribute to growth is Hyper Mall, E Retail, place in all sectionslike -Stock preparation, paper
Urbanisation of our society and the country’s machine, Utility and Waste water treatment
rising population. among others.

China, which is one of the main producers of What is your company’s main product?
kraft paper, stopped its production after the Are you exploring diversification
government banned import of waste paper into opportunities?
the country owing to environmental concerns.
How has this impacted the kraft paper industry MG Kraft Paper is our main product at present
worldwide and in India? we do not intend to expand or diversify our
product.
Chinese banon import of waste paper in their
country has impacted positively and made What is your current production capacity
imported waste paper in India and worldwide and are you looking at expansion?
affordable because China was the biggest
importer and consumer of waste paper. I presume that our machine is the smallest paper
making machine in the country. Our capacity is
Kraft paper prices have been on the rise over below 4000 MTPAand we want to maintain the
the past one month. What do you attribute same capacity no expansion no diversification.
this rise in prices to? How much has it increased
and how do you see it moving in the days to What according to you are the key
come? challenges confronting the Indian kraft
paper industry?
No, it is not right to say that prices are increasing
we can say it is ‘FLUCTUATING’ and tracking Small Kraft manufacturing units in the country
the waste paper prices which is the main and face a lot of challenges. Small paper mills are
major raw material for kraft paper. Kraft paper not getting technological support from anywhere
prices increase or decrease as per the rise or drop except from IPPTA which is providing us not
in raw material prices; so it means that prices are only technological support but providing us an
fluctuating and not increasing. appropriate platform as well.Smaller mills are
not getting any finical incentive for technological
There have been talks of a supply crunch of upgradation. Moreover, standardising of
Kraft paper due to higher exports to China. quality parameter is not there which isone of
What is the total capacity or production of kraft the prerequisites for theindustry. Our biggest
paper in India? How big is the domestic market? challenge is raw material shortage and no one
How has exports been growing? knows how to overcome this.

There is a small quantity which is being exported
to China. Approximately total manufacturing
capacity is 60lakhMTPA and production and
consumption is 5 lakh MTPM. This exportis
helping to revive idle capacity and also helping
new Kraft manufacturing unit being added every
year.

IPPTA - The Official International Journal // Volume 30 No. 3 // July - September 2018
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Key Note Speaker

Rajat Gupta

Senior Partner, Mumbai

Leads McKinsey’s energy and materials work in Asia, helping companies in emerging markets
transform their performance, achieve breakout growth, and become global leaders.
Rajat is a leader in McKinsey’s global energy and materials sector. Since joining McKinsey, Rajat has
lived on three continents and served clients in 15 countries, including China, India, Indonesia, the
Netherlands, South Africa, Thailand, the United Kingdom, and the United States.
Rajat has worked with leading companies in the metals, chemical, infrastructure, mining, power, oil,
and telecommunications sectors. He brings particular expertise in operational transformations and
change programs, leveraging digital tools in these areas. Rajat has also served clients on business
building (including digital businesses), marketing, organization, and strategy. He leads McKinsey’s
relationships with two of India’s top five conglomerates, serving them across the globe.
Rajat also leads the firm’s work with the central government, working across multiple ministries—such
as those for aviation, railways, roads, and shipping—on major programs and transformations.
Rajat is committed to building long-term relationships with Indian companies based in emerging
markets, helping them transform their performance and grow to become global leaders. For example,
his involvement with a leading Indian metal company spans 20 years of building better operations,
creating a stronger performance culture, and engendering marketing excellence across Asia, Europe,
and India. Today, the company is a global leader in its industry.
Passionate about sustainability and resource productivity, Rajat has published work on poverty, carbon
abatement, and water in India; been on the jury for several awards; and served on several industry
and government committees on sustainability. He is on the board of the Indian think tank CSTEP and
the governing board of the Childline India Foundation. Rajat leads McKinsey’s social-responsibility
efforts through Generation, the world’s largest demand-driven skilling initiative, and is a member of
the McKinsey Global Institute advisory council.
Rajat was awarded gold medals for securing first place in both his MBA and engineering degrees at
two of India’s top schools.

Message

Sanjay Singh

Chairman Organising Committee - IPPTA
Divisional Chief Executive ITC Ltd, PSPD, Secunderabad

Indian Pulp & Paper Industry has come of age in adopting technological advancement, reflection of
which was evident from last two IPPTA sessions, one focussing on Innovation, followed by the other
on Efficient and Environment Friendly Operations.
Keeping with the trend and the general mood in Pulp & Paper industry, the theme for the present
seminar in aptly chosen as “Automation for Process, Asset, Productivity, Quality and Market
optimisation”, with the subtle focus on emerging technology scenario and 4th Industrial Revolution.
After utilisation of water and steam power in production, followed by development of mass
production systems, as 1st and 2nd Industrial Revolution respectively, the third Industrial Revolution
took advantage of the developments in electronics and information technology in the form of
automation. While the manufacturing sector in the developed world and a few organisations in India
have started moving towards 4th Industrial Revolution, coined as Industry 4.0, Indian Pulp & Paper
Industry largely resides in Industry 3 era, with only a few in the advanced phase and making initial
move towards industry 4.0.
Pulp & Paper Industry in India is currently on a growth path; Being on a growth path has its own
challenges – as volume growth needs to match with better quality, on time delivery, reduced cost,
addressing environmental concerns and effective use of automation helps in meeting such needs.
Therefore, Indian Pulp & Paper Industry needs to move faster towards full-fledged automation and
pave the way for embracing the next industrial revolution.
To my mind, that is the only way to maintain the growth momentum.
It is heartening to find that IPPTA received a large number of entries for presentation of technical
papers in the current seminar. Such response clearly indicates the mind-set of the Industry and its
professionals towards use of automation and advanced technology, which is a very positive signal.
I hope the deliberations during the seminar will be very enriching for everyone.
This is also the best time of the year to visit Hyderabad and I hope that the participants will find their
stay in the city comfortable; and along with discussions on technical subjects they will have time for
fun & frolic and opportunity to create great bonhomie among the industry professionals.
I thank all the Pulp & Paper Industries, speakers, delegates, guests, sponsors and organisers for their
active participation and support and wish the seminar a great success.