![Detailed Project Report (DPR) on paper mill [kraft paper, duplex board, art paper, maplitho paper]](https://www.eiriindia.org/image/project-report/detailed-project-report-cma-data.png)
Industry Overview
Waste paper recovery is a traditional and important practice in the paper and paperboard manufacturing industry. Waste paper provides a significant source of fibrous raw material and can reduce dependence on conventional pulp supplies. The report notes that waste paper contributes about 30 percent of the fibrous raw materials consumed in paper and paperboard mills in the U.S.A., Europe and Japan.
For countries with limited forest resources, including India, the recovery and utilization of waste paper is particularly important. Waste paper, agricultural residues such as bagasse, rice husk, wheat husk, jute sticks and grasses, and other unconventional fibrous materials can supplement available raw materials for pulp and paper production. Jute sticks are highlighted as a suitable raw material because they can produce comparatively hard paper with relatively high tensile strength, while the required chemicals are available indigenously.
The report also emphasizes the role of mini paper plants in India. Compared with large-scale units, mini paper plants require less capital, chemicals and power and can utilize waste paper, rags, cereal straw and agricultural residues. Although the quality of paper may be somewhat inferior to that produced by large-scale plants, mini units can effectively augment domestic production and utilize otherwise underused fibrous resources. Improved waste-paper recovery and appropriate raw-material development are therefore important for supporting sustainable growth in the paper industry.
Cost Estimation
| Cost Parameter | Value |
|---|---|
| Plant Capacity | 150 Ton/Day |
| Land & Building (48,000 sq.mt.) | Rs. 33.32 Cr |
| Plant & Machinery | Rs. 49 Cr |
| Working Capital for 2 Months | Rs. 26.21 Cr |
| Total Capital Investment | Rs. 114.25 Cr |
| Rate of Return | 40% |
| Break Even Point | 44% |
Content Index
- INTRODUCTION
- 1. SHORTAGE OF FIBROUS RAW MATERIAL
- 2. HIGH PROCESS AND SHORTAGE OF CHEMICALS
- USES AND APPLICATION
- BESIDES, THE END USE OF PAPER AND PAPER PRODUCTS ARE,
- STANDARD QUALITIES OF WASTE PAPER
- GROUP A - ORDINARY QUALITIES.
- MIXED PAPER AND BOARD NO. 2:
- MIXED PAPER AND BOARD NO. 3:
- BOARD CUTTINGS:
- MILL WRAPPERS:
- CORRUGATED CONTAINERS:
- MIXED PAMPHLETS AND MAGAZINES:
- OVER ISSUED PAMPHLETS, BROCHURES AND MAGAZINES IN BUNDLES
- COLOURED LETTER (OR COLOURED RECORDS)
- LIGHT COLOURED LETTERS (OR LIGHT COLOURED RECORDS)
- WHITE PAMPHLETS, WITHOUT CARD BOARD
- WHITE PAMPHLETS WITHOUT CARD BOARDS, WOOD FREE:
- GROUP B - MIDDLE QUALITIES:
- GROUPE C - HIGH QUALITIES:
- B. I. S. SPECIFICATION
- B.I.S. SPECIFICATION FOR KRAFT PAPER
- SCOPE
- GRADES
- REQUIREMENTS
- MATERIAL
- FINISH
- SIZE AND TOLERANCE ON SIZE
- PHYSICAL REQUIREMENTS:-
- TABLE 1 REQUIREMENTS OF KRAFT PAPER
- TABLE 2 OPTIONAL REQUIREMENTS OF KRAFT PAPER
- PACKING AND MARKING
- PACKAGE
- ROLL
- USES & PROPERTIES OF DUPLEX BOARD
- GC DUPLEX BOARD
- GC1 BOARD
- GC2 BOARD
- GD DUPLEX BOARD
- GT DUPLEX BOARD
- BOOKBINDING BOARD
- APPLICATION OF DUPLEX BOARD
- GSM RANGE
- MARKET OVERVIEW OF PAPER INDUSTRY
- CONSUMPTION BY COUNTRY
- PAPER & PAPERBOARD PRODUCTION & CONSUMPTION FOR NEPAL
- MARKET POSITION OF KRAFT PAPER
- GLOBAL KRAFT PAPERS MARKET CLASSIFIED ON THE BASIS
- OF REGION AS FOLLOWS:
- COATED PAPER AND THEIR VARIETY
- VARIETIES
- MACHINE-FINISHED COATED PAPER
- COATED FINE PAPER
- STANDARD COATED FINE PAPERS
- LOW COAT WEIGHT PAPERS
- ART PAPERS
- OTHERS
- USES AND APPLICATION OF MAPLITHO PAPER
- SPECIFICATION OF MAPLITHO PAPER
- BASIS OF PAPER MANUFACTURING
- A CONICAL REFINER MACHINE TO IMPROVE PULP QUALITY
- THE MAIN STEPS OF TYPICAL PAPER MANUFACTURING
- TECNICALITIES IN PAPER MANUFACTURING
- CHEMICAL PULPING
- MECHANICAL PULPING
- DE-INKED PULP
- THERE ARE THREE MAIN CLASSIFICATIONS OF RECYCLED FIBRE:
- ADDITIVES
- PRODUCING PAPER
- FINISHING
- PAPER GRAIN
- MANUFACTURING PROCESS OF KRAFT PAPER
- PULPING:-
- SCREENING OF THE PULP:-
- PULP BEATING & REFINING:-
- REFINING:-
- PAPER MAKING AND FINISHING:-
- FORMING OF WET WEB:-
- PRESSING THE WET SHEET:-
- DRYING THE SHEET:-
- PROCESS FLOW DIAGRAM FOR MANUFACTURE OF KRAFT PAPER FROM WASTE PAPER
- FLOW SHEET OF MANUFACTURE OF PAPER
- FORMING OF WET WEB, PRESSING THE WET SHEET AND DRYING THE SHEET
- METHOD OF PREPARATION OF DIFFERENT TYPES OF PULPS
- SEQUENCES IN PAPER MANUFACTURING
- STOCK PREPARATION
- PAPERMAKING PROCESS
- COATING PROCESS
- FINISH PROCESS
- PROCESS OF MANUFACTURE [WRITING AND PRINTING PAPER]
- THE DIFFERENT SYSTEMS MAY BE DESIGNED AS FOLLOWS:-
- STOCK PULPED AT LOW DENSITY AND FIBERIZED BY RAPID PUMP CIRCULATION:-
- SCREENING AND RIFFLING:-
- WASHING:-
- BLEACHING:-
- BEATING:-
- SHEET LIFTING:-
- PAPER COUCHING:-
- PAPER DRYING:-
- PAPER PRESSING:-
- PAPER CLEANING:
- PAPER GLAZING:-
- SURFACE SIZING:-
- DEINKING OF WASTE PAPER:-
- SECONDARY FIBER PULPING:-
- HIGH-DENSITY-TYPE SECONDARY PULPING SYSTEMS THAT IS AVAILABLE
- THERE ARE TWO BASIC STEPS IN THE DEINKING.
- ALL DEINKING SYSTEMS HAVE THE FOLLOWING STEPS:-
- VERTICAL CIRCULATION DEINKING WITH BREABEN BEATER
- TESTING PAPER
- A. MOISTURE
- 1. MOISTURE CONTENT
- 2. SUBSTANCE BASIS WEIGHT OF PAPER.
- 3. THICKNESS OF CALIPER:-
- BULK
- THICKNESS IN MICRONS
- 4. TENSILE TEST:-
- 5. BURSTING STRENGTH:-
- THE SHOPPER SALEN TESTER
- EXPRESSION OF RESULTS
- 6. POROSITY:-
- SIZING AND ABSORBENC TESTS
- 7. PROCEDURE:-
- 8. OPTICAL PROPERTIES:-
- GLOSS
- OPACITY
- BRIGHTNESS
- COLOUR
- OPTICAL BLEACHING AGENTS
- SMOOTHNESS
- MANUFACTURING PROCESS OF COATED DUPLEX BOARD
- RAW MATERIAL SELECTION
- FLOW DIAGRAM TOP LINER
- FLOW DIAGRAM PROTECTIVE LINER
- FLOW DIAGRAM BOTTOM LINER
- FLOW DIAGRAM FILLER LAYER
- POLLUTION CONTROL IN PULP AND PAPER INDUSTRIES (IN DETAIL)
- PROCESSES AND CHARACTERISTICS OF LIQUID EFFLUENTS:-
- COMMON PULPING PROCESSES
- CHEMICAL CHARACTERISTIC OF EFFLUENT FROM
- A LARGE SULPHATE (KRAFT) PULP AND PAPER MILL USING CHEMICAL RECOVERY
- POLLUTION CONTROL FOR LIQUID EFFLUENTS
- INPLANT MEASURES
- PROCESS CHANGES:-
- COMPLETE MACHINERY MANUFACTURERS /SUPPLIERS FOR PAPER PLANT
- SUPPLIERS OF RAW MATERIALS
- WASTE PAPER
- CAUSTIC SODA
- ALUM
- ROSIN
- LIME POWDER
Appendix
- APPENDIX – A:
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
The main raw materials include waste paper, rags, agricultural residues and other fibrous materials suitable for pulp production. The report specifically discusses waste paper, bagasse, rice husk, wheat husk, jute sticks and grasses as important sources of fibre. Selection depends on the required paper quality, fibre characteristics, availability and processing method. Waste paper is particularly useful because it provides prepared fibre that can be repulped, while agricultural residues can supplement conventional fibre resources where forest-based raw materials are limited.
Waste paper is important because it supplements the fibre requirements of paper and paperboard manufacturing while reducing dependence on conventional pulp. Recovered paper can be repulped and processed into new paper products, making it a valuable secondary fibre resource. This is particularly relevant in countries with limited forest resources or difficulties in obtaining inexpensive fibrous raw materials. Effective collection and recovery systems can also reduce the quantity of paper waste lost through decay or disposal and support more efficient utilization of available fibre resources.
The basic process involves pulping, screening, refining, sheet formation, pressing and drying, followed by finishing operations as required. Waste paper is first disintegrated in water to form a fibre suspension. The pulp is then screened to remove unwanted materials and may undergo refining, deinking, bleaching or other treatment depending on the desired product. The prepared stock is formed into a wet web, mechanically pressed to remove water and dried. Additional coating, sizing, glazing or finishing can be applied according to the paper grade and end-use requirements.
Mini paper plants are smaller-scale paper manufacturing units designed to produce paper while using relatively lower capital, chemical and power requirements than large-scale plants. They can utilize waste paper, rags, cereal straw and other agricultural residues as raw materials. Their principal advantage is flexibility in using locally available and unconventional fibre resources. Although the report notes that paper quality may be somewhat inferior to that produced by large-scale units, mini plants can supplement domestic production and serve applications where premium paper quality is not the primary requirement.
Agricultural residues are used because they can provide additional fibrous raw materials for pulp production and reduce reliance on conventional forest-based resources. Materials such as bagasse, rice husk, wheat husk, jute sticks and grasses are identified in the report as potential or increasingly utilized sources. Their suitability depends on fibre strength, cellulose and lignin characteristics, processing requirements and availability. Developing these resources can be particularly beneficial in regions where conventional fibre supplies are limited, helping paper manufacturers diversify their raw-material base.
Common paper quality tests evaluate moisture, basis weight, thickness, tensile strength, bursting strength, porosity, sizing and optical properties. The report also covers measurements related to bulk, gloss, opacity, brightness, colour and smoothness. These tests help determine whether manufactured paper meets the requirements of its intended grade and application. Testing procedures and acceptance criteria vary according to the paper type and applicable specifications. Consistent testing is important for maintaining product quality during production and for verifying the performance characteristics of finished paper.
Pollution control in pulp and paper manufacturing focuses significantly on managing liquid effluents and reducing pollutant generation within the process. Appropriate measures can include process optimization, in-plant controls, recovery or reuse of chemicals, wastewater treatment and changes to processes that reduce effluent loads. The required treatment system depends on the raw materials, pulping method, chemicals used and characteristics of the wastewater. Effective pollution control should be integrated into plant design and operation to support environmental compliance and efficient resource utilization.
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