Industrial Visit Report
• Origin of HNL
• Purchase at Gate
• Wood used
• Technology Highlights
• Plant and Machinery
• Making of Paper
• Pollution Control
• Conclusion 2
Origin of HNL
• This Project was
conceived, as early as, in
• Feasibility Report was
• GoI took the decision in
May, 1970 to approve
this Project in principle
• In 1983, Kerala
• The Indian government
directed HPC to promote
and incorporate as a
• Under the Companies Act,
1956, took over and operate
the said Newsprint Mill and
to acquire all the properties
and assets as well as all the
debts and liabilities
belonging to the Newsprint
• HPC promoted and
Newsprint Limited (HNL) as
its fully owned Subsidiary
Products & Product History
• Newsprint is used in the printing of newspapers, flyers, and other
printed material intended for mass distribution.
• Diversity in range
– Initially, the company produced 52 GSM (Grams per Square Meter)
– Later commenced production of 48.8 GSM newsprint & 45 GSM
– Colour Standard / Pink, Brightness 55 - 58 %, ISO Size of reel 34 cm to
• At the time of commissioning in 1982, newsprint had 48-50 %
– Later, it adopted a superior and eco-friendly technology in bleaching
using Hydrogen Peroxide (H202).
– Enhanced the brightness to 53-55% ISO.
– further advanced the brightness levels and is at present producing
newsprint with 55 - 58 % ISO. 4
Purchase at Gate
• The Purchase at Gate scheme was launched
by HNL as a complementary, programmed to
Farm Forestry scheme. As per this scheme,
pulp wood materials are purchased directly
from farmers at a remunerative price at the
company gate doing away with middlemen.
• Highlights of the HNL Purchase at Gate Scheme:
• Launched in the year 1998.
• Direct purchase of raw materials from farmers.
• Farmers can bring in pulp wood directly to HNL gate and collect the
• No middlemen involved – farmers get fair price for their produce.
• Swings in the market do not affect the farmers as the demand from5
Wood used ….
• Pulpwood like Eucalyptus, Acacia, Mangium
etc have found an alternative market as they
are being purchased by plywood Industries
paying a very high price, this made to use
Tissue Culture bamboo
• Continuous up-gradation and improvisation in
technology for cost minimization and quality
• First Newsprint Manufacturer in India to integrate
process automation covering all the plants.
• E-practices in all functional areas viz. purchase,
distribution, finance, stores, HR, process and
• Online Digital quality control system.
• Incremental, significant technological
improvements in all critical areas. 7
• Use of Hydrogen Peroxide for bleaching.
• Installed and later upgraded the computer based
Quality Control System for Paper machine.
• FBC conversion of Boilers.
• Introduction of Distribution Control System for all mill
• Lime sludge re-burning plant for recovery of chemicals.
• Energy efficient Falling Film Evaporator and Finisher in
• Installed Fibre Optic LAN for mill-wide Computer
• Implemented Enterprise Resource Planning (ERP)
Plant and Machinery
Plant & Machinery Name of Manufacturer
Paper Machine Voith, Germany 1982
Raffinator (CMP) Sunds Defibrator, Sweden 1982
Quality Control System in Paper
Measurex, USA 1991
Chemical Additive Plant Celleir, France 1982
Andritz Filter Press (ETP) Andritz, Austria 1993
Roll wrapping Machine Klienewefers, Germany 1982
Core making Machine Guschy Tannesmann 1982
Machine winder Jagenberg, Germany 1982
Turbo Generator BHEL, Hyderabad 1982
Power Boiler ABB 1982
Recovery Boiler BHEL, Trichy 1998
Evaporator - I L&T, Mumbai 1982
Evaporator - II Alfalaval, Pune 1994
Major Process Control Systems
DCS for Utility Plant
Yokogawa Blue Star,
DCS for Pulp Mills &
Yokogawa Blue Star,
Quality control System
for Paper Machine
• HNL is one of the well performing PSUs in
the State which is continuously registering
profits since 1990.
Financial Year 2008-2009
Production 10,8005 MT
Sales 87,476 MT
Sales Turnover Rs 297.67 Cr
Profit Before Tax Rs 21 Cr
Profit After Current
Rs 12.64 Cr
• Three grades of pulp:- Chemi Mechanical pulp,
Chemical pulp and De-inked pulp are blended to
Chemi Mechanical Pulp (CMP)
• CMP plant (Sunds Defibrator, Sweden)
• Uses hard wood(Eucalyptus , Acacia) chips to produce pulp.
• Chips are washed, pre-steamed and impregnated with caustic
• Impregnated chips is mechanically pulped using three
• Raffinators are driven by synchronous motors of 6.5 MW
• Spent chemicals are removed after primary refining using
Twin roll press.
• Pulp after second stage refining is washed and bleached by
• Bleached pulp after refining is sent to High Density storage
tower for onward use in paper machine. 13
Chemical Pulping (CP)
• Capacity of CP plant is 100 MT/day.
• Reed/ Bamboo chips are pulped using
conventional KRAFT.(Sodium Peroxide+ Sodium
• After counter current washing, pulp is bleached
using chlorine followed by Hydrogen Peroxide stage.
De-Inking Plant (DIP)
• Uses Old Newspaper and Old Magazine Paper.
• Waste paper is weighed and pulped in Batch Pulper
and stored in Dump Tower.
• Pulp is cleaned off the contaminants using HD
• A seven cell floatation process removes the ink
• Pulp is then bleached using Sodium Hydro-
Sulphite and stored in High Density storage
• A Reject handling system separates the rejects
for disposal at about 50% dryness.
• The sludge handling system thickens the ink
sludge to 40% dryness for use in our FBC
Making of Paper
• The CMP, CP and DIP are mixed in a
definite ratio and chemical additives are
• The paper machine approach flow
system consists of four-stage centri-
cleaner, primary fan pump and a variable
speed secondary fan pump and pressure
• The paper machine is the modern high speed
machine from VOITH, Germany.
• With the desired velocity, the diluted pulp flows
from a high turbulance W-type head box into
Duoformer twin-wire forming section.
• The paper web is formed in Duoformer and it is
pressed to remove water with swimming rolls.
• The paper from the press section passes on to a
dryer section, with 36 dryers and one sweat dryer,
having thermo-compressor steam and condensate
• The dried paper surface is smoothened through a
four roll stack. 18
• The machine is designed for 750 meters per minute
(mpm) speed with a deckle (width) of 6.85 meters
to produce 44 to 54 GSM newsprint.
• The machine has a sectional D.C. drive with
• The finishing line has a VOITH winder, Jagenberg
Salvage winder and Klienewefers roll wrapping
machine. Paper core is made here in a spiral core
making machine with purchased kraft paper and
• The steam requirement is met by 3 boilers with
fluidised bed burning.
• There is a chemical recovery boiler of BHEL make.
• There are two turbo generators with capacity of 15
MW and 7 MW.
• Only 35% of total power requirement is met
through State Electricity Board.
• The mill has an effective water and air supply
system for plant use and controls.
• Unfailing attention on control measures and constant
monitoring on the results
• Air pollution - Fully functional electrostatic precipitators
for all the boilers and lime kiln.
• Water pollution - Fully equipped effluent treatment
plant. Quality of effluent discharge meets with all the
norms specified statutory regulations / guidelines.
• Land pollution - Construction of a secured land fill
facility for hazardous waste disposal.
• Integrated process automation covering all the plants-
First Newsprint Industry in India to implement the
• E-practices in all functional areas viz. purchase,
distribution, finance,stores,HR,process and
• In keeping with National priorities and increasing
social obligations, HNL is ISO 14001 certified and
has adopted environmental and pollution control
• The colour and other pollutants are removed and
water free from pollutants is discharged into the
• Air pollution is also controlled by effective Electro
Kerala state energy conservation award 2013
National Energy Conservation Awards-2005
Awarded with “Two Leaves” rating in Pulp & Paper category in the
Green Rating exercise conducted jointly by Union Ministry of
Environment & Forests (MoEF) and Center for Science &
Environment (CSE) in the years 1999 and 2004.
HNL has bagged the Kerala State Pollution Control awards in 1997-
98, 1999-2000 and 2002 for the best pollution control measures and
processes adopted in the mill.
A survey of the Indian Pulp and Paper Industry, the first-ever "Green
Rating" exercise in the country by the Centre for Science and
Environment (CSE) and supported by the Union Ministry of
Environment and Forest and the United Nations Development
Program (UNDP) has rated HNL among the first five environment
friendly paper mills.
HNL is the only mill in the country, which, in addition to
meeting all parameters for effluent treatment, de-
colourizers the effluent before discharge
HNL is also the first to substitute 90% of chlorine in
bleaching with environment friendly
Recycling , have helped to preserves forest materials
from about 10,000 Ha. of land.
Implementation of farm forestry with the active
participation of Voluntary / Non Governmental