Shah Paper Mills Limited 2012

Project Report
ON

Shah Paper Mills Ltd.

Under The Guidance Of Dr. Rana Singh & Ashok .Z. Shah (Executive Director- Shah Paper Mills Ltd.)

PREPARED BY: Priyanka Thakar (0120114) MBA (2011-2013) (BLOCK IV SEMESTER II)

AURO UNIVERSITY OF HOSPITALITY AND MANAGEMENT STUDIES

Manufacturers of KRAFT PAPER & BOARD

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Shah Paper Mills Limited 2012

Index
Sr. No. 1 2 3 4 5

Table of Contents
General Information of Shah Paper Mills Limited Size and Form of the Unit Product Planning Inventory Planning Manufacturing Process 5.1 Pulp Making 5.2 Conversion of pulp paper 5.3 Finishing Operations 5.4 Flow Chart/ Sheet 5.5 Images of production process Products of the company Production Process Steps Pg no: 24 Samples of the product Pg no: 25 Images of product rolls Pg no: 25 Laboratory Handling Images of the machines in the laboratory for SPC Pg no:30 Supply Chain Management Chart of SCM Time Keeping Contribution of unit to the Industry Pollution control Conclusion Appendix (Viper Report)

Page. No. 3 5 6 7 8 9 10 10 11 13 24

7 7.1 8 9 10 11

29

36 37 38 39

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1. Introduction
Shah Paper Mills Limited is one of the most renowned mills in Paper and it has achieved an immense success in Industrial Sector. SPML was certified in 1990 and it commenced its business in 1992. It started with a capital of 1, 00,000 Rs. And now its Turnover is 150 crores. Shah Paper Mills Limited produces MG (Machine Glazed) Craft Paper. Earlier Craft Paper were made up of agricultural products such as, Bagas, Rice Straw, Wheat Straw. But production through these raw materials is very Hazardous to environment also availability of the same is not in ample amount, on the other hand if paper is produced by such raw material the Production Cost increases and thus it affects the MRP of the product. Hence, Shah Paper Mills Ltd has developed new way of producing it, i.e. production with the help of just one raw material i.e. WASTE PAPER. Waste paper is recycled here, and all the impurities such as Sand, Pins, Plastic, etc. is removed and from that purified waste paper M.G Craft Paper is made. Shah Paper Mills Limited is an ecofriendly plant as waste paper is its Raw Material. Uses of waste paper are as under:- In making 1. 2. 3. 4. 5. Corrugated Boxes. Paper Tube. P.O.Y Tube. Fiber Drum. And Gum Tape.

Major users of this Product are 1. Yarn Industry (Textile) 2. Chemical Industry 3. Consumer Products Major companies with whom SPML deals are: 1. 2. 3. 4. 5. HUL. Reliance. ITW. Marico Industries Ltd (Manufacturers of Parachute oil). PepsiCo India. Page 3

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SPML is also ISO certified. ISO 9001:2008. Scope of Registration: Manufacturing and Supply of Papers. Certificate No: 91/Q/5372. Original Registration: 8th June 2009. Certificate Expiry date: 7th June 2012. Some of the General Information of the company is: 1. 2. 3. 4. 5. Incorporation: 1990. Year of Production 1992. Plant: Vapi District, Gujarat. General Products: MG Craft Paper. Location of the Unit: Plot No: 5202, III Phase, GIDC Vapi, Tal. Pardi District, Valsad.

Key Executives of Shah Paper Mills Limited Mr. Mahendra H. Shah Executive Director Mr. Girish S. Shetty Executive Director Mr. Ashok Z. Shah Executive Director Mr. Bhupendra D. Patel Executive Director Mrs. Meher C. DeSouza Company Secretary

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2. Size and Form of the Unit
SPML is a company incorporated under the Indian Companies Act, 1956 and working since last 20 years. The Firm consists of approximately 405 employees working in the unit (Vapi).

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3. Product Planning
Shah Paper Mills Ltd are manufacturing Machine Glazed (MG) craft paper which is a basic raw material for manufacturing corrugated boxes, paper tube, fiber drum, gum tape. The major users of these products are, Yarn Industry. Chemical Industry. Consumer Products.

These products are planned in various sizes and qualities such as 16BF, 18BF, 20BF, 22BF, 24BF, and 28BF (BF Burst Factor) in yellow and green color. There are two types of machines in SPML which is very important tool in product planning, as orders exceeding to machines capacity are not undertaken. Machine Specification: 1. 90 inch and 2. 120 inch Product is made order wise, hence the CEO takes the orders from the firms in advance, commit them a delivery date and next day production begins as per schedule given by the CEO. Priority basis of Bursting Factor and GSM are, 1. Lower to higher Bursting Factor. & 2. Higher to lower Bursting Factor. If there are more orders for coming delivery date related to first priority all the machines are operated on the same, that day second priority orders are not undertaken. Raw Material is also very important factor in product planning. The basic material is Waste Paper .There is two types of raw materials, Indian and Imported. If order of product is of rich quality then machine is loaded with 80% Imported material and 20% Indian material. If the orders are normal, but the client company is producing heavy goods like refrigerators, AC, T.V, then machine is loaded with 50% of Indian & 50% of Exported material. Henceforth, Prices also varies according to the order and type of waste paper used to make the same. If order of Party (client company is urgent then current machine roll is offered to them. This is how product planning is done; it is completely dependent on customer orders and the intensity of urgency. Manufacturers of KRAFT PAPER & BOARD Page 6

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4. Inventory Planning
Inventory Planning is done in such a way that inventory is bought in the Godown which is consumed within month. Hence monthly planning is done, till the time present inventory is utilized; next lot is on the way. This is how unnecessary storage of inventory and blocking of funds is avoided. Since production is based on orders of the client company is not able to maintain Just in Time (JIT). Furthermore, when the inventory/ raw material enter the premises of the company be it imported material or regular Indian waste paper, they have a policy, where in it is compulsory for every departmental head to come at the godown and check the quality and quantity of raw material. When managers give approval only the payment is made to the vendor

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5. Manufacturing Process
A brief note regarding the manufacturing process converging production , utility& service department of the product:-

Manufacturing of company is broadly divided into:1) Pulp making from waste paper (basic raw materials) 2) Paper making 3) Finishing and packaging

The company is in the manufacturing of mg kraft paper by recycling of the waste paper. The basic raw materials, which are:1) 2) 3) 4) 5) 6) Imported waste paper Indigenous waste paper Chemical used in the process Starch powder, gaur gum power - to increase strength of the paper. Alum, rosin- to maintain water absorbency (COBB). BF deformer- to kill the foam generated in the process.

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5.1 Pulp making from waste paper

Pulp making is the first process in the manufacturing of craft paper. Pulp is made up of the basic raw materials i.e. recycled waste paper. The waste paper of different quality is fed into high consistency pulper in the required proportion depending on the quality of the kraft paper to be manufactured. The waste paper is put on the conveyor belt, which takes the material to the HC pulper the waste paper is mixed with the black water (effluent treated water) under vigorous stirring process in the pulper by high consistency operating rotor. After achieving 16 percent of the consistency of pulper in the HC pulper, It is then fed to the pour unit, the pulp is then further treated with black water to bring the consistency of the pulp to 2 percent also with the help of perforate screen plate and rotor impurities like wooden pieces, plastics of big sizes and other foreign materials is drained out through drain valve automatically with the help of pneumatically operated valve. The semi cleaned pulp containing little bits of plastic and sand is then pumped into the dump with the help of pour pump where this pulp is stored. The semi cleaned pulp is fed to HD cleaners and turbo separators to remove the finer impurities like sand and small bits of plastic. The impure pulp is then sent to cleaning system consisting of HD cleaners and turbo separators where the foreign particles such as plastics, twine sand, grit, removed from the pulp. Then the pulp is thickened to desired concentration with the help of thickener. This pulp is treated into refiners to attain properties into final paper. Pulp is sent to section known as stock preparation section. The pulp is suitably treated in to two operations as required for the particulars grade of paper tube made from it. Firstly beating operation gives the required strength to the paper and Secondly, chemical treatment to give desirable characteristics such as smoothness brightness strength. The pulp after beating and mixing with chemical is ready for paper making known as stock.

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5.2 Conversion of Pulp Paper
The ready pulp is then send to paper machine and where the pulp flows in a highly water diluted form on to an endless web of woven wire cloth. The wire cloth removes the bulk quantity of water from the stuff by suction and pressure. Then the wet paper sheet is pressed in press section to remove excess water. When the paper sheet comes out of the press, it is passed through the Rotary cylinders, known as dryers. Therefore, the sheet passes through MG cylinder which gives glaze to one side of the paper. Then the sheet is passed through post dryer section to dry the paper to attain required moisture.

5.3 Finishing Operations

The paper sheet formed as above is Fecon calendaring machine for more thickness. The paper sheet is then wound up to jumbo rolls on Pop Reel. The jumbo rolls are placed in rewinder machine to bring the paper in the form of reels as per specification of customers. These reels are packed and dispatched to customer in reel form.

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Conveyor Belt

5.4 Flow Sheet

Pulper

Pump

Chest

Pump

H.D Cleaner

Vibrating Screen

Turbo T-500

Turbo T- 400

Thickener

Chest

Pump

Rousing Tank

Alum Tank

Magnetic Trap Pump Refiner Pump

Chest Manufacturers of KRAFT PAPER & BOARD

Mixing Chest Page 11

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Pump Machine chest Pump Refiner Regulating Box Fan Pump Cleaner Head Box Wire Part Press I Press II Pre- Dryer M.G After Dryer Pop Reel Rewinder

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Step wise Images of entire production process of Shah Paper Mills Limited.

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Step 1: Raw Material Manufacturers of KRAFT PAPER & BOARD Page 14

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Step 2: Processing Raw Material Manufacturers of KRAFT PAPER & BOARD Page 15

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Step 3: Removing Impurities from Raw Material Manufacturers of KRAFT PAPER & BOARD Page 16

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Step 3: Continued

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Step 3: Continued

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Step 4: Generating machine

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Step 5: Actual production with the pulp

Step 6: Water supply

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Step 7: To shape the product with the help of water.

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Step 7: Continue..These are Rollers to shape the product

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Step 8: Actual moisture less product

Step 9: Formation of Mother roll. Manufacturers of KRAFT PAPER & BOARD Page 23

Shah Paper Mills Limited 2012

6. Products
SPML Produces MG Kraft paper which is produced in different sizes as detailed under: BF( Bursting Factor) 16 18 20 22 24 28 28 GSM(Grams Per Square Meter) 120-150 120-180 120-180 120-200 120-200 120-200 201-250 Nature Natural Shade Natural Shade Natural Shade Natural Shade Natural Shade Golden Yellow Golden Yellow

Production Process is conducted by following steps: Client Orders

Directors (Here director fixes price, quality and quantity of product as per order of the customer, delivery date is also decided at this stage)

Programmer (Enters Transaction in records)

Production Site

Dispatch

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Shah Paper Mills Limited 2012

Samples of Shah Paper Mills Products and Images of Final Product in the Mill

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Shah Paper Mills Limited 2012

Mother Roll

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Three sizes offered by SPML from Mother Roll

Products in the godown

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Shah Paper Mills Limited 2012

Transportation of the product

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7. Laboratory Handling/ Quality Control
When the product is ready, it is tested in laboratory to see whether product is made exactly according to customer order or not. Laboratory handling is done by Mr. PM Patel. There are many types of machines that are used to check the quality of the product, so as to maintain the quality of the product. Explanation of various machines: 1. Crush Tester: To check the thickness of the product. 2. Tear Tester: Here the product is place on the machine, and it is torn on it and then on the basis of Time taken to tear the product calculations is done. GSM is calculated in this stage. There are different specifications for different types of the product. 3. Cob Testing: In this stage cob is adjusted as per customer requirement, the reading of this machine helps in determining water absorbency of the product. 4. Oven: To Check the moisture of the product. 5. Brushing strength Machine: After calculating GSM with the help of tear tester BF (Bursting Factor) is read. Exact checking is done whether it is as per customers specifications or not on this stage. This is how product is tested before dispatch. However, if in case any deviations are found in all the stages of testing, then Customer is informed about the deviations, and if he permits to dispatch the lot then order is dispatch with some Discount. And if the Customer denies accepting a little deviated product then the whole lot is sent back to the First stage of production, or that inferior quality product is given to whomsoever it is useful.

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Images of the Laboratory, and all the machines with the help of which SPC is carried out at Shah Paper Mills.

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7.1 Supply Chain Management
Supply chain management of Shah Paper Mills is very well managed. There are several companies which require Kraft paper, and Mills for Kraft paper are very few, they have oligopoly system, in which they decided that Mills will supply their products only to the Agents, then it is the job of the agent to distribute the orders to the clients Company, thus entire transport is in hands of the agents. In this process the Paper Mills have to handle only few agents, (where agents compile the orders and order sizes, and then ask the paper mill to produce the same

Process of SCM
Agents take the order from various clients.

They communicate with director of the mill regarding order acceptance, date of delivery, and pricing.

Production process is carried out.

Once product passes through laboratory/ quality check, it is transported to the Agent.

Agent arranges for trucks & truck drivers which is again totally outsourced.

Goods are loaded in the trucks/ tempo and delivered to the customer or Client Company.

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8. Time Keeping Department
Time keeping department plays a very important role in every business. Absence of time keeping department, is uncompensated. This department helps in maintaining regularity of an employee which is very important to increase effectiveness and efficiency of the organization. It helps in utilizing human resources fully as to avoid wastage and this result in enrichment the goal of the company. In shah mills ltd time keeping is handled by H R department itself by the H R manager Anil Koli. Strict policy is adopted by the manager so as to maintain discipline in the organization. In shah mills, employees working hours are up to 8 hours a day. On a day there are three shifts all of 8 hours. Shifts are bifurcated as:Shift 1:- 7am to 3pm Shift 2:- 3pm to 11 pm Shift 3:- 11pm to 7am In shah mills time keeping is handled as follows:1. Reporting:Reporting is done by security at the gate through punch card system (online). Reporting time is as per shift 2. Late entry:Is the employ is late , 10 mins flexibility is available . i.e. is the employee is late for 10 mins he/she is allowed to enter. After this no employ is allowed to enter even if there is a genuine reason. In this case the employee have to contact Anil Koli , the manager and if he feels the reason genuine , only then he can order the gate keeper to give him entry else he is marked as absent for the day and affects his salary . 3. Punch card system:When an employee is allotting for his card to be punched by the gate keeper he is recognized by the camera which is connected to the HR manager office computer, so managers can know who entered at what time. This avoids in accidents such as theft and maladjustment etc. This is how strict time policy is handled by shah paper mills to maintain discipline and avoid conflicts in the organization. Manufacturers of KRAFT PAPER & BOARD Page 38

Shah Paper Mills Limited 2012

9. Contribution of unit to the industry
Shah paper mills have made largest contribution to industry as it is an ecofriendly plant. A shah paper mill produces paper but not with the help of trees and agricultural residual, it manufactures its products with the help of waste paper. In the process of manufacturing water plays a very significant role, it is used in excess, thus to save water, shah paper mills have recycling technology in the plant itself. So water can be used again. This way SPML satisfy its customer by making excellent paper and on time delivery, but not at the cost of environment deterioration. Pollution Control Water can be recycled only up to certain limit, when it becomes impossible to use the same again then that dirty water is sent to Vapi Waste Control & Management Company. This company has their own Common Effluent Treatment Plant (CEPT). Here dirty water is sent, for which SPML have to pay accordingly, which means they have outsourced the pollution control technique. SPML has also taken permission from GPCB i.e. (Gujarat pollution control board) for production purpose and this consent is renewed every 5 years as per the consent of the Company.

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10. Conclusion
Shah Paper Mills is considered as one of the renowned unit in paper industries. On my visit I was satisfied with all the information provided regarding the operations of the unit, I had least knowledge about the unit and now after completion of this project I have learnt a lot. The company is well versed and is attaining huge turnovers. Furthermore, in this cut throat competitive world this unit is gaining an overall success, not only in India but also overseas. Hence according to my view this company is developed in all the aspects and has a great future, and I am very glad knowing about the industry as a whole via this project.

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