Birla Cellulose is a manufacturer of cellulosic fibers that takes a 360 degree approach to sustainability across its entire value chain. This includes responsible sourcing of wood, sustainable pulp and fiber manufacturing processes certified by various standards, product certifications, social and community programs, and full traceability through its supply chain. Birla Cellulose engages with stakeholders and communities through programs focused on safety, education, women's empowerment, and infrastructure development to build a more sustainable future.
Dr. Aspi N. Patel: A Steadfast Leader Pioneering Innovation
SAC - Birla Cellulose 12-Oct-15
1. 1
“Cellulosic from Start to Finish”
Manufacturing Innovations
Presentation by
Rohan Batra
Special Projects and Sustainability
Dated 15th Oct 2015
2. 2
AB Group – Taking India to the World
• A US $ 43 billion MNC, 50 companies across 6 continents in 36 countries
• Over 130 manufacturing units, 53% revenues from international operations
• Anchored by 136,000 employees, 42 different nationalities
• Ranked No 4 in Global “Top Companies for Leaders” survey (Aon Hewett, Fortune Magazine)
• Businesses encompass leadership in metals, cement, telecom, financial services, branded apparel,
textiles, yarns, fibres, etc
Birla Cellulose manufactures Man Made Cellulose Fibres - Viscose, Modal, Excel, Spun-Dyed
• Pulp in Canada, Sweden and India
• Fibre in India(4), China, Thailand, Indonesia
• Fully integrated Supply Chain for Chemicals, Power, Engineering & Employees.
• R&D spanning sapling to fashion
4. 4
Aditya Birla Group – Sustainability Focus
Sustainability Vision
“By 2017, the Aditya Birla Group
endeavours to become the leading
Indian conglomerate for sustainable
business practices across its global
operations.”
1. Responsible
Stewardship
2.
Stakeholder
Engagement
3.
Future-Proofing
by Creating Value
Brand Vison
The circle signifies the cycle of “nature &
sustainability”
Birla Cellulose - Leaves fall & grow all over again,
they are a renewable resource of nature.
5. 5
Birla Cellulose: 360 degree Sustainability Engagement
Birla Cellulose – 360
degree Approach
1. Raw Material
•Responsible Wood
Sourcing Policy
2. Manufacturing
Process:
Pulp & Fibre
•Life Cycle Assesment
•R&D Leadership
3. Product
•Okeo – Tex 100
•REACH Compliance
4. Social –
Labour/Education
•SA 8000
•Sedex
5. Community
Village development
CSR Programs
6. Traceability
•LIVA Accredited
Partner Forum
•Backward
Intergration
6. 6
Forest Management Programs - Certifications ( FSC, PEFC, SFI) and Third
party NGO
Pulp Sustainable programs –
1. LCA for process
2. Certifications
3. Safety and community
Programs
Fibre Sustainable Programs:
1. In addition, Product
certifications – Okeo-Tex
100, REACH etc
LAPF Support Programs -
1. Business sustenance service support
2. Transparency, Traceability and Visibility through the Value
chain
Co- Marketing Programs -
1. Sustainability backend
ownership
2. Consumer space.
connect
Birla Cellulose – Supply Chain for Sustainability Engagement
7. 7
Seedling stage
1. Raw Material - Responsible Wood Sourcing
BC strictly adheres to environment laws & regional
regulations
BC does not purchase wood harvested from High
Conservation Value Forest
Working closely with Canopy on the vision – ‘Fashion
loved by Forest’
SFI certificate
PEFC certificate
FSC certificate
Source: SLU (The Swedish University of Agricultural Sciences)
The carbon absorbed and released by the
forest over the lifecycle
8. 8
2 - Sustainablity Through Pulp Manufacturing process
Wood to Pulp Conversion
• LCA - AVN, AVC and Domsjo Units by Control Union
• The Domsjo Unit – Zero Discharge unit.
• Byproduct 1- Sawmill chips, Saw dust and Bark go into fibre
• Byproduct 2 - Bark and Sieving dust go into power plant
FY 13 FY 15
Power Consumption
(KWh / T Pulp)
FY 13 FY 15
Steam Consumption
(T/T Pulp)
• Improvement in Steam & Power
Consumption
Percentage change – 4.5% Percentage change – 7.1%
9. 9
1. LCA for 7 Fibre Units and 5 distinct fibres - partnered by Global Consultants, Control Union, SGS, SimaPro
2. MMCF exhibit better LCA backed by environmental performance - Water, land and energy consumption is lower
3 - Sustainability through Fibre Manufacturing process
FY 13 FY 15
Steam
Consumption
(T/T Fibre)
FY 13 FY 15
Water
Consumption
(M3/T Fibre)
Material
Sustainable Closed Loop Programs in the
Plants to Ensure ZERO discharge
Wood Pulp - RM • Conversion into Fibre
CS2 - RM
• Maximum through Condensation
• Remaining gases passes through controlled
technology. i.e. WSA Scrubbers & Genosorb.
Caustic /
Sulphuric Acid -
RM
•Recovery in terms of conversion to Sodium
Sulphate
Zinc – RM
• Converted into inorganic sludge.
• ETP having primary and secondary
treatment.
Sodium Sulphate
- By Product
• Paper, Glass, Detergents, Textile dyeing,
Tanning, Pharmaceuticals, Freezing reagent
& Ceramic Industries
% change – 4.9% % change – 4.6%
Improvement in Steam &
Water Consumption
10. 10
4 - Sustainability through Product Innovation
Water Saving
up to 70
lts/kg
Reduced
Effluent
Load 70%
Power Saving up
to 3.5-4.0 KW
Time Saving
6-8 hrs/ Batch
Spundyed VSF Reduces Processing Cost as it
ensures Better 1st Grade Processed Fabric
Production – Better Profits
- Natural base
- Biodegradable
- Oeko-Tex100 for all fibres
- Safe for baby articles
Birla Cellulose Fibres Spun-Dyed Fibres
Gas
Saving/Batch
100-115 Kg
Steam
Saving/Batch
450-500 kg
11. 11
5b. Supplier Integration Linkage – Backward Integration
Birla Cellulose –
Manufacturing
Sites
Energy
Power
Chemicals
Man -
Power
LAPF -
Partners
Supplier Integration Buyer Integration
12. 12
5b. Supplier Integration Linkage – Backward Integration
Birla Cellulose –
Manufacturing
Sites
Energy
Power
Chemicals
Man -
Power
LAPF -
Partners
Supplier Integration Buyer Integration
Birla Cellulose – Fully Integrated Supply Chain
Increased Efficiency in terms of Cost, Time, Distance, Man
Power & Production. Reduction in Production foot-print
13. 13
Environmental Sustainability Support
Spinners Fabricators Processors
Business Sustenance through service support
5a. LAPF : A Robust Ecosystem for 360 Degree Sustainability
Traceability & Visibility Through Chain
Parameters
Industrial Stand
ards
Challenges & Work Process to set LAPF Standards
pH Values 5.5 – 9
• Use of high caustic is seen in industry like other fibres. Shared
best levels product-wise.
• Choosing of chemicals, technology and good ETP shared
• Project cost and ROI supported
COD, (Mg/L) < 250
BOD (5 days at 20 degree
C) Mg/L
< 30
TDS (Mg/Litre) <2100
14. 14
Safety
WASH
CSR
Employees, Staff
Govt.
Authorities &
Policy makers
NGOs, Local
Communities
Customers, Value
Chain Partners
Shareholders,
Investors
Suppliers,
Service
Providers
6a - Sustainability through Stakeholder Engagement
1. Apex level Safety Council Team
2. Safety observation program - Biannual
3. The WBCSD (World Business Council for
Sustainable Development) - Water and
Sanitation, Hygiene (WASH)
4. Score improved to1.7/2.0 now
15. 15
6b. Engagement with Communities & Society
Women Empowerment:
• Vocational training
• Handicraft
• Handlooms
• Home based businesses
• Loans
Education & Infrastructure:
• Focus in Rural India
• Hospitals
• Schools
• Girl-child Education
• Adult education programs
16. 16
There are many shades of green.
Collaborative Association Today, to perform for a Better Tomorrow
Rohan Batra
Special Projects - Sustainability
Birla Cellulose
E : rohan.batra@adityabirla.com
+91 8108032464