1. EXAMPLE CASE STUDY OF A PULP & PAPER
INDUSTRY IN TAMIL NADU THIS IS PRESENTED WITH
THANKS TO M/S TNPL
Citizens Charter
Department of Industries
TAMIL NADU NEWSPRINT AND PAPERS LIMITED
( http://www.tnpl.co.in/ )
OUR COMPANY
Tamil Nadu Newsprint and Papers Limited (TNPL) was
formed by the Government of Tamil Nadu in April 1979 as a
Public Limited Company under the provisions of the
Companies Act,1956. The primary objective of the company is
to produce newsprint and printing & writing paper using
bagasse, a sugarcane residue, as the primary raw material.
The Registered Office of the company is situated at 67, Mount
Road, Guindy, Chennai – 600 032.
OUR BUSINESS
The company is in the business of manufacturing and
marketing of Newsprint and Printing & Writing Papers. The
products are being marketed throughout the country and also
being exported to 20 countries around the world.
The factory is situated at Kagithapuram in Karur District of
Tamil Nadu. The initial capacity of the plant was 90,000 tpa of
Newsprint and Printing & Writing paper which commenced
production in the year 1984. The capacity was doubled to
1,80,000 tpa in January 1996 after implementation of the first
expansion project. Recently, the capacity has been further
enhanced to 2,30,000 tpa in April 2003 through upgradation of
both the paper machines.
Some of the key features of the Mill are listed below:
The largest bagasse based plant in the World and a mill
with largest production capacity in India, at a single location.
Appropriate for India, which is one of the largest sugarcane
producers in the World.
The only paper mill in India assisted by the World Bank
Doubled the capacity within a period of 10 years from
inception
State-of-the-Art paper machines with built in flexibility for
manufacturing both newsprint and printing & writing papers in
the same machine.
Unique arrangement with the sugarmills for sourcing the
raw material. in the form of exchange of steam / fuel for
bagasse.
2. OUR VISION
“To be the market leader in the manufacture of world class eco-
friendly papers by adopting innovative technologies for
sustainable development”.
OUR MISSION
Attain leadership in Paper Technology
Promote the usage of bagasse in the manufacture of
Newsprint and Printing & Writing Paper
Minimise environmental impact and become an
environment friendly organisation.
OUR COMMITMENTS
(A) ON QUALITY:
Quality Policy : “TNPL is committed to manufacture and supply eco-
friendly papers to customers‟ satisfaction with emphasis on continual
improvements in its quality management system”
Meeting customer requirement with Eco friendly raw materials (viz
bagasse) for paper making, through continuous process
improvements is the aim of TNPL‟s Quality Policy. Quality
standardization without compromise on environment is being
accomplished with online quality control at various stages of
production. Despite opening-up of Indian markets for imports, TNPL
has been consistently recording increase in exports year by year,
which demonstrates the company‟s commitment to Quality. Direct
interaction with the customer through customer service cell has helped
the company in meeting the customer satisfaction with Customer
Satisfaction Index (CSI) ranging from 7.01 to 7.50. Customized
products are also being manufactured by TNPL to meet the customer
delight.
TNPL has obtained the ISO 9001 certification from RWTUV of
Germany for development, manufacture and supply of Newsprint and
Printing & Writing Paper. Steps have been initiated to move further
towards ISO 9001-2000 series standards.
The Online Integrated Information System (OIIS) a mini ERP package
developed by CMC Ltd for TNPL integrates the flow of information
from all the sections of the company covering production, materials,
finance, marketing etc. This OIIS has greatly improved information
transfer for faster and timely decision making for assured product
quality. The automated process control facilities ensure complaint free
products at various stages up to the final packing and despatch.
TNPL‟s in-house Research and Development facility is recognised by
the Department of Scientific and Industrial Research (DSIR) New
Delhi. The R&D department has sophisticated state-of-the art
instruments and equipments.
(B) ON ENVIRONMENT
ENVIRONMENT POLICY OF TNPL
3. Produce eco-friendly quality papers adopting innovative
technologies
Provide a cleaner environment by sustained R&D efforts
and continued process improvements
Comply with all relevant environmental legislation and
regulation
Conserve and optimise the usage of resources viz., power,
water, fossil fuels and raw materials like bagasse and wood
Impart training to promote and motivate our human
resources to be environmentally responsive
The above Environment Policy has been approved and adopted by
the Board which clearly demonstrates the commitment of the company
towards genuine sustainable development and the “ Minimum impact
–best process ” philosophy.
ENVIRONMENT PROTECTION
By using bagasse as the primary raw material instead of
wood, TNPL is saving deforestation of about 30000 acres of
forest land every year.
Due to the usage of bagasse the chemical consumption in
the pulp bleaching process is lower
TNPL‟s effluents completely comply with the norms set by
Tamil Nadu Pollution Control Board. TNPL is adopting state-
of-the-art activated sludge treatment system. Further the
treated effluent water is being used to irrigate 1500 acres of
land abutting the factory. The farmers are cultivating cash
crops such as sugarcane, groundnut etc using TNPL effluent
water. By this process “ A full Cycle is completed “ as depicted
below:
THE FULL CYCLE
The company has never used wood from natural forests.
Wood is being sourced only from Farm forestry.
Engaged the services of Tamil Nadu Agricultural University
(TNAU), Coimbatore for continuous monitoring of land
irrigated with TNPL effluent water.
Comprehensive Environmental impact assessment study is
undertaken once in 5 years, through National Environmental
Engineering Research Institute (NEERI).
Water consumption per tonne of paper has been brought
down from 124 KL in 1999-2000 to 105 KL in 2002-03. During
the current year 2003-04, this has been further reduced to 73
KL. 80% of the water drawn from the river is being supplied
back for irrigation as treated effluent water.
Solid Waste Management:
Fly ash generated at the power boilers is being sold to the
cement plants
Effluent sludge is being sold to the Board manufacturing
units
4. Lime sludge generated is being recycled in the Lime Kiln
TNPL has obtained the prestigious ISO 14001 Certification from
RMTUV, Germany for “Successfully establishing and applying
environmental management system for development, manufacture
and supply of paper”.
This certification duly acknowledges TNPL‟s commitment for
environment protection and sustained efforts to minimise the overall
environmental impact.
(C) ON ENERGY CONSERVATION
ENERGY MANAGEMENT POLICY OF TNPL
Maximise the usage of eco-friendly agro waste fuels for
generation of energy
Continue improvements in processes and equipments for
efficient generation and usage of energy
Involvement of all employees for cost reduction in
generation of steam and power and efficient utilisation of the
same
Contributing to the energy needs of the State and export
the surplus power
Reduce the specific energy consumption by 2% every year
for 5 years through various energy conservation measures.
TNPL is 100% self sufficient in power generation through the 61.18
MW Power Generation Capacity (TG Sets) installed at the paper mill
site. The surplus power generated is being exported to the State Grid.
TNPL also generates green power through the 18 MW wind farm
installed at Devarkulam and Perungudi of Tirunelveli district. The
entire power generated at the wind farm (about 270 lakh units per
annum) is being exported to the State Grid.
TNPL also believes in prudent utilisation of bio fuels. Entire pith
generated while depithing the bagasse, is being fired in the boilers as
fuel. Besides the company is also using many agro fuels such as
coconut shell, rice husk, saw dust, coffee husk etc. The usage of
above agro fuels has substantially reduced the consumption of fossil
fuel.
Installed a Bio-methanation plant to generate methane gas from the
effluent water (bagasse wash water) and use it as fuel as substitute
for furnace oil in the lime kiln saving 10 KL of furnace oil every day.
Energy Conservation measures:
Energy conservation is an ongoing process at TNPL. Some of the
measures taken in this regard are given below :
Installed Variable Frequency Drives where the process
requires variation in speed of the drive.
Installed energy efficient motors and reduced the motor
capacity in many areas after continuous review.
5. Installed high efficiency pumps in key areas.
Enhanced the economizers‟ capacity in power boilers to
reduce flue gas temperature and improve the boiler efficiency.
(D) ON HUMAN RESOURCES DEVELOPMENT
TNPL realises that the continued success of any organisation
depends on a healthy human resources policy. TNPL‟s Human
Resources policy focuses upon enthusing the human resources to be
innovative to keep ahead of competition. As an enlightened employer
the company has always been concentrating on optimizing the labour
productivity and continuous efforts have been taken to improve the
same. Some of the initiatives by the company in line with the above
objectives are given below:
In-house training programmes are conducted on topics like Team
Building, Personality Development, Safety, Inter-personnel skills,
productivity and so on. Besides the employees are also being
sponsored for training programmes in the relevant areas organised by
reputed Institutions.
Performance Appraisal plays a significant role as a tool and technique
of Management development and growth. Key Result Areas (KRA)
have been identified and responsibility, accountability, objectives and
targets are defined for these KRAs. The results of these KRAs are
reviewed on continuous basis and corrective measures initiated
appropriately.
The philosophy of Total Quality Management (TQM) integrating all
activities of the organisation coupled with a customer-centered focus
has been taken-up. Suitable projects have been identified and
implemented.
Company is nurturing a participative atmosphere of redressing the
grievances of the employees for ensuring peaceful working
environment.
Amicable Wage settlements are reached with the Trade Unions and
harmonious industrial relationship is being maintained.
TNPL is providing direct employment for 1788 persons and indirect
employment for about 5000 persons
(E) ON SOCIAL DEVELOPMENT
The Company has taken several steps for promoting the overall
betterment of the abutting villages. Providing drinking water facilities,
construction of retaining walls in the irrigation channels, laying &
improving the road & culverts, provision of lighting facilities, park
development, supply of equipments & instruments to Fair Price shops
& schools are some of the projects completed by the company in this
regard. TNPL is also conducting free medical camps in the
surrounding villages on a monthly basis. TNPL functions in harmony
with the local community.
(F) ON SAFETY
TNPL has a clearly defined Safety Policy. The policy specifies in
detail the responsibility for implementation of safety measures,
prevention of personal injury, accident reporting and statutory
reporting system. The Safety committee consists of members from
Management and workmen. Periodic committee meetings are
6. conducted and suggestions are implemented. Safety Audit is
conducted to ensure the effectiveness of the safety systems in
position.
(G) ON ACHIEVING EXCELLENCE
Achieve full capacity utilisation following the latest
productivity techniques and developed technologies.
Continuous upgrade of the technology.
Improve the quality of the paper to that of international
standards.
Develop new products with good quality at reasonable
prices by adopting innovative and persistent R&D efforts.
Build brand equity with branded value added products
Become globally competitive in terms of cost, pricing and
quality
Provide cleaner environment by following the best practices
of ISO 14001 Environment Management Systems
TNPL MARKETING
The broad product range of TNPL is given below:
NEWSPRINT
PRINTING & WRITING PAPER:
Creamwove
Superprinting
Hitech Maplitho
Excel Maplitho
Ultawhite Maplitho
Magazine Printing
COPIER PAPER
TNPL Copier
TNPL OS 2000
TNPL Eco-Friendly Note Books
Newsprint is normally manufactured in 49 Gsm reels and directly sold
by the company to the various newspaper establishments such as The
Hindu, Malayala Manorama, Ananda Bazaar Patrika and so on.
Printing & Writing paper (PWP) is manufactured in reel and sheet
forms with the Gsm (Grams per square meter – basis weight of the
paper) varying from 50 to 80. Various sizes of reels and sheets are
also cut to suit the customer requirements. Some of the major end-use
segments of PWP are printing applications, note books, computer
stationery, office stationery, etc. The major distribution channels for
PWP are given below:
Sale through Indentors
Direct Sales
Export
7. TNPL is having the Indentor network covering the length and breadth
of the Country. The indentors procure order from a customer and are
responsible till the payment is received by the company.
TNPL is also making direct sales to certain major customers. Some of
the major direct customers are Navneet Publications, Tamil Nadu Text
Book Corporation, Director of Stationery & Printing etc.
Apart from the above, TNPL is also exporting about 15% of the PWP
production to 20 countries around the World.
THE EXPORT NETWORK
1. Australia 11. Philippines
2. Egypt 12. Singapore
3. Greece 13. Sri Lanka
4. Indonesia 14. Sudan
5. Jordan 15. South Africa
6. Kenya 16. Taiwan
7. Malaysia 17. Turkey
8. Myanmar 18. U.A.E
9. Nepal 19. U.K
10. Nigeria 20. Yemen
TNPL is having marketing offices at the major cities of the Country to
regulate the marketing activities. Regular customer meets are
arranged for continuous customer feed back and corrective action.
During 2002-03 the company has produced and sold 20496 tonnes
of Newsprint and 147349 tonnes of Printing & Writing Paper. Of this,
25932 tonnes of Printing & Writing Paper was exported valuing Rs
76.88 crores.
TNPL has been maintaining “Zero Stock” status of finished product
ie paper at the end of the respective Financial Years for the past 13
years.
Symbolic of TNPL‟s commitment to the environment, the World Wide
Fund for nature (WWF) has entered into a pact with TNPL to use the
„Panda‟ logo in TNPL‟s branded products.
The quality complaints on paper manufactured by TNPL are received
at Corporate Office and Factory Office at the following address:
Corporate Office Factory Office
Thiru S Krishnamurthi Thiru C Subramanian
Dy General Manager (Mktg.) Manager (Marketing)
TNPL TNPL
67 Mount Road Kagithapuram-639136
Guindy Karur District
Chennai -600 032 Tel No.04324- 277001 to 20
Tel No.22354415-20 Fax No.-04324- 277028 to 29
Fax No.22350834 / 22354614
The quality complaints are attended within a maximum of two weeks.
Wherever necessary, the company deputes its marketing and quality
control personnel for attending the complaints and redressing the
customers' grievances.
TNPL NET WORK IN INDIA
8. AWARDS AND ACCOLADES
“BEST PAPER MILL 2001-02”
TNPL has been given the prestigious award “Paper Mill of the year
2001-2002” for TNPL‟s overall performance, approaches for meeting
social obligations, ensuring global competitiveness, sustainable
development & technology options by the Indian Paper Manufacturers‟
Association, New Delhi.
“ENVIRONMENT PROTECTION”
Recognising TNPL‟s concern for the environment, the Rotary Club of
Chennai (East) and Earth Care, bestowed the “Dr M.S. Swaminathan
Award for Environment Protection 2002” on TNPL.
“EXPORT AWARD” & STATUS
TNPL has bagged the CAPEXIL “SPECIAL EXPORT AWARD” for
the fourth consecutive year, for its outstanding export performance
during the year 2001-02.
The Government of India has given “TRADING HOUSE” status to
TNPL recognising the export performance.
TNPL has been bestowed the “ Niryat Shree Award” by Federation of
Indian Export Organisation (FIEO) for the high degree of excellence it
has demonstrated in exports.
RATING UPGRADE BY CRISIL
Credit Rating Information Services of India Ltd (CRISIL) has upgraded
the rating of TNPL‟s Fixed Deposit Program from FAA to FAA +
indicating the high degree of safety .
SAFETY AWARD
TNPL was awarded the commendation award on “CII Leadership &
Excellence Award in Safety,Healthy & Environment (SH&E) year
2002” during the month of February 2003.
ENERGY AWARD
TNPL has bagged the National Energy Conservation Award for the
year 2001 from Government of India, recognition of its outstanding
achievement in energy management.
BEST CORPORATE CITIZEN
Loyola Institute of Business Administration
(LIBA) Chennai has adjudged TNPL as the “
Best Corporate Citizen 1999” and bestowed
the Mother Theresa Award by recognising its
Outstanding social commitment
Exploring eco-friendly technology
Professional Management
Customer friendly and community
caring enterprise.
9. CONTACT:
For more details about the company, products profile and other
details, please browse the company‟s web site at
http://www.tnpl.co.in/ or contact through the company‟s e-mail
address: response@tnpl.co.in
