Paper, Pulp and Paperboard Production from Bamboo

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Introduction
Bamboo is a quickly renewable resource. Bamboo is the single fastest
growing species of plant on the planet with some species growing more
than a meter a day. In sharp contrast to trees which require decades to
recover from harvesting, bamboo reaches maturity in 3 to 5 years or
less and when it is cut, the stem is left in the soil to sprout a new
shoot and start the growing process again.

Paper has been made from bamboo for hundreds of years. The
commercial process uses actual bamboo canes for pulp. Bamboo paper
is attracting the attention of companies and individuals looking for
eco-friendly printing and sustainability. Despite the digital revolution,
the demand for paper is growing globally.

The bamboo pulp is one kind of paper pulp like wood pulp, straw pulp or
reed pulp. The bamboo pulp is usually made from moso bamboo,
phyllostachys pubescens and sinocalamus affinis by sulfate digestion
process or soda process. The bamboo fiber morphology and length is
intermediate between wood fiber and straw fiber.
Bamboo pulp can be made into bamboo paper. Bamboo paper is strong
and it has wide applications. The bleached bamboo paper is used to
manufacture offset paper, typing paper and high-grade culture paper.
The unbleached bamboo paper is generally applied to package
papermaking. Besides, bamboo pulp and wood pulp can be mixed and
used to make cable paper, insulation paper, and cement bag paper.

Bamboo pulp is a kind of paper pulp. It is made from the moso bamboo,
phyllostachys pubescens and sinocalamus affinisetc, with the sulfate
digestion processand soda process. There are also tender bamboo green,
lime pickled into half-clinker. Fiber form and length, between wood and
grass fiber. Easy sizing, bamboo pulp for medium fiber length pulp, fine
and soft. The thickness of pulp is loose, the tear is high, and the
breaking strength and tensile strength are low. High mechanical
strength. Paper made of bamboo pulp, bleached for making offset
printing paper, typing paper and other advanced cultural paper,
unbleached paper for making wrapping paper, etc.

Market Outlook
The pulp and paper industry is a large and growing portion of the
world’s economy. Most of the pulp and paper mills are located near the
major waterways and have an access to a large, uninterrupted supply of
water. After using the water for pulp and paper production, these mills
discharge the used water into the waterways as waste. The pulp and
paper industry is faced with mounting environmental, political, and
economic pressures to reduce the volume and toxicity of its industrial
wastewater.

The overall demand for paper, growing annually at 6.7 per cent, is
expected to touch 20.8 million tonne in the country in fiscal year 2020-
21, driven by rising income levels, growing per capita expenditure and
rapid urbanization. The Indian paper industry accounts for about 3.7%
of the world’s production of paper. The estimated turnover of the
industry is INR 60,000 crore (USD 8.5 billion approximately) and its
contribution to the exchequer is around INR 4,500 crore. The industry
provides employment to more than 0.5 million people directly and 1.5
million people indirectly.
India is the fastest growing market for paper globally and it presents an
exciting scenario; paper consumption is poised for a big leap forward in
sync with the economic growth.

The futuristic view is that growth in paper consumption would be in
multiples of GDP and hence an increase in consumption by one kg per
capita would lead to an increase in demand of 1 million tonnes.
The demand is projected to boost to 23.5 million tonnes by 2024- 25.
India is the greatest growing market for paper in the world with a
growth rate of about 6 percent yearly. The increase of per capita paper
utilization by one kg will raise the demand by about 1.25 million tonnes
per annum.

Indian paper industry can be majorly classified
further as below:
 Newsprints: Newsprint serves the newspaper & magazines industry.
This segment forms ~15% of the domestic paper industry.
 Writing and Printing Paper: Printing and writing segment caters
to office stationary, textbooks, copier papers, notebooks etc. This
segment forms ~30% of domestic paper industry.

 Packaging Boards: Packaging paper & board segment caters to
tertiary and flexible packaging purposes in industries such as FMCG,
food, pharma, textiles etc. This segment forms ~51% of the domestic
paper industry. This is amongst fastest growing segment after Tissue
owing to factors such as rising urbanization, increasing penetration
of organized retail, higher growth in FMCG, pharmaceutical.
 Tissue: Tissue paper is majorly used as paper handkerchiefs for
facial & toilet purpose. Currently due to its low base and increasing
hygiene awareness, this segment witnessed fastest growth.

India produces many varieties of papers, namely, printing and writing
paper, packaging paper, coated paper and some speciality paper.
Varieties under printing and writing paper are creame wove paper,
super printing paper, maplitho paper (non-surface and surface size),
copier paper, bond paper and coating base paper and others. The
varieties under packaging paper are kraft paper, boards, poster paper
and others. The other varieties under coated paper art paper/board,
chromo paper/board and others. There are approximately 600 paper
mills in India, of which twelve are major players.

Global Paperboard Market
The global paperboard market, which stood at US$122.69 bn in 2015, is
prophesized to reach an estimated value of US$227.47 bn by the end of
2024. During the forecast period from 2016 to 2024, the market is
anticipated to rise at a strong 7.1% CAGR.
On the basis of its application, the market is segmented into packaging
and graphic printing. Due to its light weight property, it is very
convenient to be handled in packaging, loading and unloading. On the
other hand, due to its better printing and graphic capabilities, it is used
as an effective marketing tool for brand awareness and promotion.

Global paperboard market is expected to drive on account of growing
manufacturing and packaging industries across the globe. Several paper
pulp layers are compressed in order to make paperboard as a finished
product. They are widely used by manufacturers and retailers for
packaging purposes. Growing paperboard packaging trend is expected to
propel global paperboard market over the forecast period.
Rise in environment related concerns and issues are expected to boost
global paperboard market especially in packaging sector over the
forecast period. Paperboards are not acceptable by manufacturing units
producing large weight products for packaging activities as they are not
able to handle high stress and pressure owing to which it is expected to
hinder global paperboard market growth.

As paperboards are produced from tree pulp or wood pulp, it results in
deforestation which is expected to obstruct global market in coming
years. Stringent environment related regulations by EPA are expected
to slow down the market growth rate over the forecast period.
Global paperboard market player includes Metsa Group, Sappi Limited,
Caraustar and Cascades Inc., Oji Holdings Corporation, Shandong Bohui
Paper Group Co., Ltd, International Paper Company, Clondalkin Group,
ITC Limited, Nippon Paper Industries Co. Ltd., Paper Works Industries,
Stora Enso Oyj, Multi Packaging Solutions, Smurfit Kappa Group plc.,
Graphic Packaging International and Mondi plc. Global market is highly
fragmented in nature. Developing countries are expected to be the
major targets on account of huge global paperboard demand from
growing end use industries including packaging and manufacturing.

Bamboo pulp is very similar to softwood in terms of fiber length and
strength, however, bamboo can also be pulled together with hardwood.
Mix of softwood and hardwood will yield stronger pulp compared to
hardwood pulped separately. Bamboo wood contains high levels of
papermaking fibres because plant cell walls are composed of cellulose
which is the main material used to make paper. The structure and
shape of the cellulose bamboo wood fibre varies from species to species
and even within an individual tree.

The leading players in Asia bamboo pulp market are Ampack Corp,
Hindustan Paper, Phoenix Pulp and Paper, Panjipol Paper Industry,
Siam Cellulose, The Titaghur Paper Mills, Yibin Paper, Yaan Paper,
Guangxi Liujiang Paper, Guangdong Guangning, Guizhou Chishui,
Zhongzhu Group and others. Bamboo pulp is categorized into two
variants such as bleached pulp and unbleached pulp. Bamboo pulp is
used in the manufacture of printing paper, writing paper, tissue paper,
textiles and many more.

Machinery Photographs

Project at a Glance
PROJECT AT A
GLANCE (` in lacs)
COST OF PROJECT MEANS OF FINANCE
Particulars Existing Proposed Total Particulars Existing
Propose
d Total
Land & Site
Development Exp. 0.00 2045.00 2045.00Capital 0.00 2232.33 2232.33
Buildings 0.00 2206.00 2206.00Share Premium 0.00 0.00 0.00
Plant & Machineries 0.00 3584.58 3584.58
Other Type Share
Capital 0.00 0.00 0.00
Motor Vehicles 0.00 20.00 20.00Reserves & Surplus 0.00 0.00 0.00
Office Automation
Equipments 0.00 222.00 222.00Cash Subsidy 0.00 0.00 0.00
Technical Knowhow
Fees & Exp. 0.00 100.00 100.00Internal Cash Accruals 0.00 0.00 0.00
Franchise & Other
Deposits 0.00 0.00 0.00
Long/Medium Term
Borrowings 0.00 6696.99 6696.99
Preliminary& Pre-
operative Exp 0.00 15.00 15.00Debentures / Bonds 0.00 0.00 0.00
Provision for
Contingencies 0.00 325.00 325.00
Unsecured
Loans/Deposits 0.00 0.00 0.00
Margin Money - Working
Capital 0.00 411.75 411.75
TOTAL 0.00 8929.33 8929.33TOTAL 0.00 8929.33 8929.33

Project at a Glance
Yea
r
Annualised Boo
k
Valu
e
Debt Divid
end
Retained
Earnings
Payo
ut
Proba
ble
Mark
et
Price
P/E
Rati
o
Yield
Price/
Book
Value
EPS CEPS Per Share
Per
Share Per Share
No.of
Time
s` ` ` ` ` % ` % ` %
1-2 5.33 9.04
15.3
3 24.00 0.00
100.
00 5.33 0.00 5.33 1.00 0.00
2-
3 8.18 11.39
23.5
1 18.00 0.00
100.
00 8.18 0.00 8.18 1.00 0.00
3-
4 11.03 13.81
34.5
4 12.00 0.00
100.
00
11.0
3 0.00 11.03 1.00 0.00
4-5 13.83 16.25
48.3
7 6.00 0.00
100.
00
13.8
3 0.00 13.83 1.00 0.00
5-6 16.58 18.68
64.9
4 0.00 0.00
100.
00
16.5
8 0.00 16.58 1.00 0.00

Project at a Glance
Yea
r
D. S. C. R. Debt
/ -
Depos
its
Debt
Equit
y as-
Equit
y
Total
Net
Wort
h
Retu
rn
on
Net
Wort
h
Profitability Ratio Assets
Turno
ver
Ratio
Curre
nt
Ratio
Indivi
dual
Cumul
ative
Over
all
GPM PBT PAT Net
Contri
bution
P/V
Ratio
(Number of times)
(Number of
times) % % % % % %
Initi
al 3.00 3.00
1-
2 1.33 1.33 1.57 1.57 2.19
14.90
% 9.07% 6.48%
7793.
42
42.4
5% 1.70 0.93
2-
3 1.63 1.47 0.77 0.77 1.23
17.35
%
12.87
% 8.52%
9022.
49
42.1
2% 1.84 1.25
3-
4 1.99 1.63 1.99 0.35 0.35 0.71
19.05
%
15.61
%
10.05
%
10309
.76
42.1
2% 1.87 1.65
4-5 2.43 1.80 0.12 0.12 0.41
20.25
%
17.62
%
11.21
%
11597
.02
42.1
1% 1.81 2.12
5-6 2.97 1.99 0.00 0.00 0.24
21.11
%
19.11
%
12.09
%
12884
.29
42.1
1% 1.71 3.66

Project at a Glance
BEP
BEP - Maximum Utilisation Year 5
Cash BEP (% of Installed Capacity) 50.87%
Total BEP (% of Installed Capacity) 54.52%
IRR, PAYBACK and FACR
Internal Rate of Return .. ( In %age ) 26.01%
Payback Period of the Project is ( In Years )
2 Years 3
Months
Fixed Assets Coverage Ratio ( No. of times ) 5.544

1. What is Paper, Pulp and Paper Board
Manufacturing industry ?
2. How has the Paper, Pulp and Paper Board
Manufacturing industry performed so far and how
will it perform in the coming years ?
3. What is the Project Feasibility of Paper, Pulp and
Paper Board Manufacturing Plant ?
4. What are the requirements of Working Capital for
setting up Paper, Pulp and Paper Board
Manufacturing plant ?
Major Queries/Questions Answered in the Report?

5. What is the structure of the Paper, Pulp and Paper
Board Manufacturing Business and who are the
key/major players ?
6. What is the total project cost for setting up Paper,
Pulp and Paper Board Manufacturing Business?
7. What are the operating costs for setting up Paper,
Pulp and Paper Board Manufacturing plant ?
8. What are the machinery and equipment
requirements for setting up Paper, Pulp and Paper
Board Manufacturing plant ?

9. Who are the Suppliers and Manufacturers of Plant
& Machinery for setting up Paper, Pulp and Paper
Board Manufacturing plant ?
10. What are the requirements of raw material for
Manufacturing plant ?
11. Who are the Suppliers and Manufacturers of Raw
materials for setting up Paper, Pulp and Paper
Board Manufacturing Business?
12. What is the Manufacturing Process of Paper, Pulp
and Paper Board?

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13. What is the total size of land required for setting up
Paper, Pulp and Paper Board Manufacturing plant ?
14. What will be the income and expenditures for Paper,
15. What are the Projected Balance Sheets of Paper, Pulp
and Paper Board Manufacturing plant ?
16. What are the requirement of utilities and overheads for
setting up Paper, Pulp and Paper Board Manufacturing
plant?
17. What is the Built up Area Requirement and cost for
setting up Paper, Pulp and Paper Board Manufacturing
Business?

18. What are the Personnel (Manpower)
Requirements for setting up Paper, Pulp and Paper
Board Manufacturing Business?
19. What are Statistics of Import & Export for Paper,
Pulp and Paper Board?
20. What is the time required to break-even of Paper,
21.What is the Break-Even Analysis of Paper, Pulp and
Paper Board Manufacturing plant?
22.What are the Project financials of Paper, Pulp and
Paper Board Manufacturing Business?
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23. What are the Profitability Ratios of Paper, Pulp
and Paper Board Manufacturing Project?
24. What is the Sensitivity Analysis-Price/Volume of
Paper, Pulp and Paper Board Manufacturing
plant?
25. What are the Projected Pay-Back Period and
IRR of Paper, Pulp and Paper Board
Manufacturing plant?
26. What is the Process Flow Sheet Diagram of
Paper, Pulp and Paper Board Manufacturing
project?

27. What are the Market Opportunities for setting
up Paper, Pulp and Paper Board Manufacturing
plant?
28. What is the Market Study and Assessment for
Manufacturing Business?
29. What is the Plant Layout for setting up Paper,

Table of Contents
of the
Project Report

1. PROJECT LOCATION
1.1. DISTRICT PROFILE & GEOTECHNICAL SITE CHARACTERIZATION
1.1.1. General
1.1.2. History
1.1.3. Climate
1.1.4. Map
1.1.5. Economy
1.1.6. Industries
1.1.7. Industry at a Glance
1.1.8. Education and Health
1.1.9. Transportation
2. INTRODUCTION
2.1. PAPER
2.2. PAPER PULP
2.3. PAPERBOARD
3. CHARACTERISTICS OF PAPER
4. DIFFERENT TYPES OF PAPER
5. USES & APPLICATIONS
6. COMMON TERMS OF PAPER INDUSTRIES
7. B.I.S. SPECIFICATIONS
7.1. IS 6874~METHOD OF TESTS FOR BAMBOO

7.2. IS 1763~SUBSTANCES OF PAPER AND PULP BOARD
7.3. IS 2724~QUALITY TOLERANCES FOR WATER FOR PULP AND PAPER INDUSTRY
7.4. IS 4664~PULP BOARD
7.5. IS 5061: PART 1~GUIDE FOR TREATMENT AND DISPOSAL OF EFFLUENTS OF PULP,
PAPER AND BOARD INDUSTRIES: PART 1 - FOR MILLS WITH CHEMICAL RECOVERY
SYSTEM
7.6. IS 1064~PAPER STANDARD SIZES
7.7. IS 1848~WRITING AND PRINTING PAPER
8. MARKET SURVEY
8.1. THE INDIAN PAPER INDUSTRY
8.2. PULP
8.3. FUTURE GROWTH OPPORTUNITIES
9. TOP PAPER COMPANIES IN INDIA
10. EXPORT & IMPORT: ALL COUNTRIES
10.1. EXPORT: ALL COUNTRIES
10.2. IMPORT: ALL COUNTRIES
11. FINANCIALS & COMPARISON OF MAJOR INDIAN PLAYERS/COMPANIES
11.1. ABOUT FINANCIAL STATEMENTS OF CMIE DATABASE
11.2. PROFITS & APPROPRIATIONS
11.3. TOTAL LIABILITIES
11.4. TOTAL ASSETS
11.5. NET CASH FLOW FROM OPERATING ACTIVITIES
11.6. SECTION – I
11.6.1. Name of Company with Contact Details

11.6.2. Name of Director(S)
11.6.3. Credit Ratings
11.6.4. Plant Capacity
11.6.5. Location of Plant
11.6.6. Name of Raw Material(S) Consumed With Quantity & Cost
11.7. SECTION – II
11.7.1. Assets
11.7.2. Cash Flow
11.7.3. Cost as % Ge of Sales
11.7.4. Forex Transaction
11.7.5. Growth in Assets & Liabilities
11.7.6. Growth in Income & Expenditure
11.7.7. Income & Expenditure
11.7.8. Liabilities
11.7.9. Liquidity Ratios
11.7.10. Profitability Ratio
11.7.11. Profits
11.7.12. Return Ratios
11.7.13. Structure of Assets & Liabilities (%)
11.7.14. Working Capital & Turnover Ratios
12. COMPANY PROFILE OF MAJOR PLAYERS
13. EXPORT & IMPORT STATISTICS OF INDIA
13.1. EXPORT STATISTICS FOR WRITING PAPER
13.2. IMPORT STATISTICS FOR WRITING PAPER
13.3. EXPORT STATISTICS FOR PAPERBOARD

13.4. IMPORT STATISTICS FOR PAPERBOARD
14. PRESENT MANUFACTURERS
15. BAMBOO AS RAW MATERIAL
15.1. CHARACTERISTICS OF BAMBOO
15.2. ADVANTAGE OF BAMBOO OVER CONVENTIONAL WOOD
15.3. OVERVIEW OF BAMBOO INDUSTRY IN INDIA
15.4. BAMBOO HANDLING PROCESS AT THE BIOFUEL PLANT
15.4.1. Bamboo Handling
15.4.2. Bamboo Processing in the Biofuels Production Plant
15.5. BAMBOO SOURCING OPTIONS
15.6. CASE STUDY FOR A PAPER MILL
15.6.1. Type One Supply Chain- Grower to Paper Mill
15.6.2. Type two: Supply Chain- Grower to Retail Market
15.7. BAMBOO PROCUREMENT OPTIONS
15.7.1. Primarily Source of Bamboo
15.7.2. Regulatory and Policy Status
15.8. UTILIZATION AND MARKETING OF BAMBOO
15.9. PULPING CHEMICAL
15.10. CHEMICALS REQUIRED FOR PULP AND PAPER MILLS
16. PRODUCT DESCRIPTION
17. BLEACHING AGENTS AND THEIR CONDITIONS
18. PAPERMAKING ADDITIVES

19. MANUFACTURING PROCESS
19.1. STEPS DETAILS IN THE PULP AND PAPERMAKING PROCEDURE
19.2. POWER GENERATION AND WATER TREATMENT
19.3. CHEMICAL AND BY-PRODUCT PRODUCTION
20. PROCESS FLOW DIAGRAM
21. WATER SUPPLY AND ENERGY CONSUMPTION IN PULP AND PAPER MILLS
21.1. RAW WATER TREATMENT
21.2. PROCESS WATER TREATMENT
21.3. BOILER FEED WATER TREATMENT
21.4. COOLING SYSTEMS AND USE OF COOLING WATER
21.4.1. Preliminary Treatment
21.4.2. Primary Treatment
21.4.3. Secondary Treatment
21.4.4. Disinfection of Wastewater
21.5. ENERGY CONSUMPTION IN PULP AND PAPER MILLS
22. SUPPLIERS OF PLANT & MACHINERY
23. SUPPLIER OF RAW MATERIAL
24. PHOTOGRAPHS/IMAGES FOR REFERENCE
24.1. MACHINERY PHOTOGRAPHS
24.2. RAW MATERIAL PHOTOGRAPHS
24.3. PRODUCT PHOTOGRAPHS
25.PLANT LAYOUT
26. QUOTATION OF PLANT, MACHINERY AND EQUIPMENTS FROM SUPPLIER

Project Financials
• Project at a Glance Annexure
• Assumptions for Profitability workings ………………………..1
• Plant Economics…………………………………………………..2
• Production Schedule………………………………………………3
• Land & Building……………………………………………….……4
Factory Land & Building
Site Development Expenses

• Plant & Machinery……………………………………………..……..5
Indigenous Machineries
Other Machineries (Miscellaneous, Laboratory etc.)
• Other Fixed Assets………………………………………..........….......6
Furniture & Fixtures
Pre-operative and Preliminary Expenses
Technical Knowhow
Provision of Contingencies
• Working Capital Requirement Per Month……………………….…7
Raw Material
Packing Material
Lab & ETP Chemical Cost
Consumable Store

• Overheads Required Per Month and Per Annum………….…….…8
Utilities & Overheads (Power, Water and Fuel Expenses etc.)
Royalty and Other Charges
Selling and Distribution Expenses
• Salary and Wages …………………………………………....……..9
• Turnover Per Annum ……………………………………….....…10
• Share Capital…………………………………………………….....11
Equity Capital
Preference Share Capital

• Annexure 1 :: Cost of Project and Means of Finance
• Annexure 2 :: Profitability and Net Cash Accruals
 Revenue/Income/Realisation
 Expenses/Cost of Products/Services/Items
 Gross Profit
 Financial Charges
 Total Cost of Sales
 Net Profit After Taxes
 Net Cash Accruals

• Annexure 3 :: Assessment of Working Capital requirements
 Current Assets
 Gross Working Capital
 Current Liabilities
 Net Working Capital
 Working Note for Calculation of Work-in-process
• Annexure 4 :: Sources and Disposition of Funds

• Annexure 5 :: Projected Balance Sheets
 ROI (Average of Fixed Assets)
 RONW (Average of Share Capital)
 ROI (Average of Total Assets)
• Annexure 6 :: Profitability Ratios
 D.S.C.R
 Earnings Per Share (EPS)
 Debt Equity Ratio

• Annexure 7 :: Break-Even Analysis
 Variable Cost & Expenses
 Semi-Variable/Semi-Fixed Expenses
 Profit Volume Ratio (PVR)
 Fixed Expenses / Cost
 B.E.P

• Annexure 8 to 11 :: Sensitivity Analysis-Price/Volume
 Resultant N.P.B.T
 Resultant D.S.C.R
 Resultant PV Ratio
 Resultant DER
 Resultant ROI
 Resultant BEP

• Annexure 12 :: Shareholding Pattern and Stake Status
 Equity Capital
 Preference Share Capital
• Annexure 13 :: Quantitative Details-Output/Sales/Stocks
 Determined Capacity P.A of Products/Services
 Achievable Efficiency/Yield % of Products/Services/Items
 Net Usable Load/Capacity of Products/Services/Items
 Expected Sales/ Revenue/ Income of Products/ Services/ Items

• Annexure 14 :: Product wise Domestic Sales
Realisation
• Annexure 15 :: Total Raw Material Cost
• Annexure 16 :: Raw Material Cost per unit
• Annexure 17 :: Total Lab & ETP Chemical Cost
• Annexure 18 :: Consumables, Store etc.
• Annexure 19 :: Packing Material Cost
• Annexure 20 :: Packing Material Cost Per Unit

• Annexure 21 :: Employees Expenses
• Annexure 22 :: Fuel Expenses
• Annexure 23 :: Power/Electricity Expenses
• Annexure 24 :: Royalty & Other Charges
• Annexure 25 :: Repairs & Maintenance Expenses
• Annexure 26 :: Other Manufacturing Expenses
• Annexure 27 :: Administration Expenses
• Annexure 28 :: Selling Expenses

• Annexure 29 :: Depreciation Charges – as per Books (Total)
• Annexure 30 :: Depreciation Charges – as per Books (P & M)
• Annexure 31 :: Depreciation Charges - as per IT Act WDV (Total)
• Annexure 32 :: Depreciation Charges - as per IT Act WDV (P &
M)
• Annexure 33 :: Interest and Repayment - Term Loans
• Annexure 34 :: Tax on Profits
• Annexure 35 :: Projected Pay-Back Period and IRR

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