JK PAPER LIMITED BEST ENERGY EFFICIENCY PRACTICES AT UNIT : CPM, FORT SONGADH, GUJARAT Presentation by: Darab Khan, GM(Project & Development) Date : 21 st Aug, 2015 J K PAPER LIMITED ……. Creating eating Lasting ing Impressi pressions ons Slide No. 1
JK Paper Today An Industry benchmark with Power Packed Brands J K PAPER LIMITED ……. Creating eating Lasting ing Impressi pressions ons Slide No. 2
JK PAPER LTD IS ONE OF THE LEADING COMPANIES OF JK ORGANIZATION – A PROMINENT BUSINESS HOUSE OF INDIA FOUNDED OVER 100 YEARS AGO Paper Tyre Cement V-Belts- Oil Seals & Power USD 3.7 Billion Transmission Systems Agri Genetics 23 manufacturing plants Present in 80 countries Dairy Products More than 30,000 employees Clinical Research Hospital & Health Education Defence Electronics services J K PAPER LIMITED ……. Creating eating Lasting ing Impressi pressions ons Slide No. 3
JK’S BRANDS ARE INDUSTRY BENCHMARKS IN RESPECTIVE PRODUCT CATEGORIES PLANTS WITH STATE OF THE ART TECHNOLOGY AND MINIMAL ENVIRONMENTAL IMPACT Panoramic view of the Unit JKPM (Orissa) -295,000 tpa) Copier Paper (Market Leader – 26% Share) Coated Paper ( Amongst top Two – 9% Share) Panoramic view of the CPM (Surat, Gujarat) – 160,000 tpa Packaging Board ( Amongst top Two – 16% Share) J K PAPER LIMITED ……. Creating eating Lasting ing Impressi pressions ons Slide No. 4
STRATEGIC GEOGRAPHICAL PRESENCE Total Production Capacity • Strategic location Saleable Product : 455,000 tons per annum (tpa) Pulp : 275,500 tpa (BD) – JKPM located close to raw material sources – CPM located close to large end customers & port • Strong distribution reach – 4 regional offices UNIT : CPM – 11 warehouses Pulp (tpa) 60,500 UNIT : JKPM Paper (tpa) 55,000 – 180 distributors Pulp (tpa) 215,000 Pkg. Boards (tpa) 90,000 Paper (tpa) 295,000 – over 4,000 dealers Combined strength of ~ 4800 employees at both the locations J K PAPER LIMITED ……. Creating eating Lasting ing Impressi pressions ons Slide No. 5
VISION,MISSION & CORE VALUES J K PAPER LIMITED ……. Creating eating Lasting ing Impressi pressions ons Slide No. 6
INTRODUCTION TO JK PAPER, UNIT: CPM JK Entered in paper business in 1938. JKPM was set up in Odisha in 1962 JK acquired CPM In 1992, and turned around it by the year 1994-95. Paper business consolidated in 2000-01 under JK Paper Ltd. Packaging Board Plant commissioned in 2007 J K PAPER LIMITED ……. Creating eating Lasting ing Impressi pressions ons Slide No. 7
POST TAKEOVER PERIOD JK took over the Management in July 1992 After rehabilitation full production of Pulp & Paper started in 94-95 Company’s worth became positive in June 1996 & Company came out of BIFR purview on 17 th February 1997 JK Paper Mills (Paper undertaking of JK Corp Ltd.) transferred as a going concern to the Company from 1 st April 2000 Company’s name changed to JK Paper Ltd. on 5 th November 2001 Substantial expansion – Packaging Board Plant of 60,000 TPA with energy efficient CFB and TG – 12 MW at a Capital Cost of Rs.300 Cr. Commissioned on February 17, 2007 and commercial production started from October 21, 2007. CPM’s present Capacity of Paper & Board is 1,45,000 TPA. J K PAPER LIMITED ……. Creating eating Lasting ing Impressi pressions ons Slide No. 8
STRATEGIES ADOPTED TO OVERCOME THE CHALLENGES Product development & Product up-gradation Production capacity enhancement Technological improvement Organization Development interventions & effective Human Resource Management Training & development Innovations & continuous improvement Implementation of TPM Implementation of Process Based Organization (PBO). Development of in-house strength for de-bottlenecking and Low Cost solution. Infrastructure development Strong team work Focus on CSR activities J K PAPER LIMITED ……. Creating eating Lasting ing Impressi pressions ons Slide No. 9
JOURNEY OF OPTIMAL PERFORMANCE . Trend of production Capacity Enhancement Low production due to unfavourable market Increase in Paper & Board Production Capacity condition & change in 450 productmix 400 408 394 350 385 380 359 343 300 TPD 302 250 200 150 142 143 147 147 100 140 138 141 128 127 50 0 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 Years Increase in Pulp Production Capacity Increase in Paper Production Capacity Increase in Board Production Capacity Low production due to 200 Low production due to 3 0 0 unfavourable market unfavourable market 249 condition & change in condition & change in 180 243 243 237 productmix product mix 180 2 50 166 207 166 191 157 159 155 155 160 154 2 0 0 160 150 152 152 157 150 TPD 148 147 147 145 141 143 142 139 139 TPD 141 140 150 138 137 140 140 127 128 127 123 10 0 120 118 115 120 120 TPD 108 50 100 100 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 Years Years Years J K PAPER LIMITED ……. Creating eating Lasting ing Impressi pressions ons Slide No. 10
Best Practices in Energy Efficiency J K PAPER LIMITED ……. Creating eating Lasting ing Impressi pressions ons Slide No. 11
UTILITY CONSUMPTION PER TONE OF PRODUCT (SALABLE PULP + PAPER + BOARD) Before Energy After Energy Percentage (%) of Particulars Unit Saving Schemes Saving Schemes Reduction Year (2010-11) Year (2014-15) Power KWH/T 937 922 1.60 consumption Steam T/T 7.33 6.91 5.73 consumption Water consumption m3/T 50.80 45.17 11.08 Coal consumption T/T 1.428 1.437 -0.63* Own Power % 97.82 98.88 1.08 generation Grid Power % 2.18 1.12 48.63 consumption * Coal consumption increased due to use of lignite (Law quality fuel) J K PAPER LIMITED ……. Creating eating Lasting ing Impressi pressions ons Slide No. 12
SEC TARGET PAT FIRST CYCLE Value PAT first Unit Trend of SEC Target PAT First Cycle 0.70 cycle 0.601 0.60 0.57 SEC of a base MOET 0.601 0.524 year Average of 0.50 2007-08,2008- 09,2009-10 0.40 MOET 0.30 Target of SEC MOET 0.57 (Assessment year 2014-15) 0.20 0.10 SEC achieved MOET 0.524 PAT 0.00 (Assessment Base Year Target Assessment Target Achieved Year 2014-15 2014-15 year 2014-15) J K PAPER LIMITED ……. Creating eating Lasting ing Impressi pressions ons Slide No. 13
ENERGY SAVINGS SCHEMES IMPLEMENTED Trend of Energy Savings Schemes Implemented Year No. of Total Savings 33.22 35.00 scheme Investme Rs. Million s nt 30.00 Rs. 28 Million 25.00 2011-12 13 1.87 5.80 20.00 14.87 13.75 2012-13 28 3.05 33.22 14 12.33 15.00 13 10.18 10 2013-14 14 13.75 14.87 10.00 9 5.8 4.76 3.45 3.05 5.00 1.87 2014-15 10 4.76 10.18 0.00 2011-12 2012-13 2013-14 2014-15 2015-16 (Apr- Jun'15) 2015-16 09 3.45 12.33 No of Schemes (Apr- Total Investment Rs. Million Savings Rs. Million Jun’15 J K PAPER LIMITED ……. Creating eating Lasting ing Impressi pressions ons Slide No. 14
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