POM Project Block 4 Sem 2

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Shah Paper Mills Limited 2012

Manufacturers of KRAFT PAPER & BOARD

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





Index

Sr.

No.Table of Contents

Page.

No.

1 General Information of Shah Paper Mills Limited 3

2 Size and Form of the Unit 5

3 Product Planning 6

4 Inventory Planning 7

5 Manufacturing Process 8

5.1 Pulp Making 9

5.2 Conversion of pulp paper 10

5.3 Finishing Operations 10

5.4 Flow Chart/ Sheet 11

5.5 Images of production process 13

6 Products of the company

Production Process Steps Pg no: 24

Samples of the product Pg no: 25

Images of product rolls Pg no: 25

24

7 Laboratory Handling Images of the machines in the laboratory for SPC Pg no:30 29

7.1 Supply Chain Management

Chart of SCM

8 Time Keeping 36

9 Contribution of unit to the Industry

Pollution control

37

10 Conclusion 38

11 Appendix (Viper Report) 39





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. Corrugated Boxes.

2. Paper Tube.

3. P.O.Y Tube.

4. Fiber Drum. And

5. 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. HUL.

2. Reliance.

3. ITW.

4. Marico Industries Ltd (Manufacturers of Parachute oil).

5. PepsiCo India.





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. Incorporation: 1990.

2. Year of Production 1992.

3. Plant: Vapi District, Gujarat.4. General Products: MG Craft Paper.

5. 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

http://investing.businessweek.com/research/stocks/private/person.asp?personId=107242318














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).





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.





4. Inventory Planning

Inventory Planning is done in such a way that inventory is bought in the Godown which is

consumed within ½ 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





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) Imported waste paper

2) Indigenous waste paper

3) Chemical used in the process

4) Starch powder, gaur gum power - to increase strength of the paper.

5) Alum, rosin- to maintain water absorbency (COBB).

6) BF deformer- to kill the foam generated in the process.





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 pumpedinto 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.





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 sectionto 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 reelsare packed and dispatched to customer in reel form.





Conveyor Belt

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 Pump

Refiner

Chest Mixing Chest

5.4 Flow Sheet





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





Step wise Images of entire production process of Shah Paper MillsLimited.





Step 1: Raw Material





Step 2: Processing Raw Material





Ste 3: Removin Im urities from Raw Material





Step 3: Continued





Step 4: Generating machine





Step 5: Actual production with the pulp

Step 6: Water supply





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





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





Step 8: Actual moisture less product

Step 9: Formation of Mother roll.





6. Products

SPML Produces MG Kraft paper which is produced in different sizes as detailed under:

BF( Bursting Factor) GSM(Grams Per Square Meter) Nature

16 120-150 Natural Shade





28 120-200 Golden Yellow

28 201-250 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





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

Mill





Mother Roll





Three sizes offered by SPML from Mother Roll

Products in the odown





Transportation of the product





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 customer’s 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.





Images of the Laboratory, and all the machines with the help of which SPC is

carried out at Shah Paper Mills.





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 client’s 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.





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, employee’s 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.





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.



Shah Paper Mills Limited 2012 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.

POM Project Block 4 Sem 2

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