GVG Paper
GVG Paper
INTRODUCTION
1.1 INTRODUCTION
Paper gets its name “papyrus”, a read that the ancient Egyptian used for making a writing
material, they cut papyrus stalks into steps and pressed crises crossed layers of the strips into
sheets.
The paper industry was established in Baghdad around 795.A.D. French man named
“Nicholas Louis Robert” invented a machine. To make paper as continuous roll rather than
sheets. The word paper which is obtained from the Greek word “papyrus” originated in China.
Paper is an important material tool to plan and execute any work in this world.
Indian paper industry is struggling to get raw materials at effective price as there is no
government policy to favour paper industry for forestation and also at importing pulp. Though
quality of final product remained a concern till few years had been sorted out with advanced
technology. Among the larger mills, TN Newsprint and Century Pulp and Paper already have
recycled fibre. Internationally, recycled paper forms 30% of the component as raw materials.
Indian paper industry makes a small 1.5% of the global production of paper and paper
board with a size of around 5.5 billion dollars. The industry was delicenced in 1997 by the
Government of India and made foreign participation permissible. Most of the paper mills are in
existence for a long time and hence present technologies fall in a wide spectrum ranging from
oldest to the most modern. The mills use a variety of raw material eg. Wood, bamboo, recycled
fibre, bagasse, wheat straw, rice husk and recycled fibre. India is the fastest growing market for
paper globally with paper consumption set to rise with the economic growth and is estimated to
touch 14 million tons in the next 5 years (source IPMA).
Paper recycling has several benefits. Using recycled paper to make new paper reduces the
number of trees that are cut down, conserving natural resources. In some instances, recycling
services are chapter than trash – disposal services. Recycling paper saves landfill space and
reduces the amount of pollution in the air from incineration. In India, however only about 20%
waste paper is being currently recovered annually. Low recovery is on account of alternate use of
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paper in wrapping, packing, etc. lack of source segregation results in waste paper getting
contaminated and becoming unusable.
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CHAPTER – II
INDUSTRY PROFILE
The name paper derives from the name of the papyrus plant, however, the methods of
production are different. Paper is made of pulped cellulose fibres (usually cotton, flax, or wood),
whereas papyrus is made of sliced sections of the inner pithy body of the flower stem of the
papyrus plant, laid in two layers at right angles, pressed together and dried.
According to tradition, paper was first made in AD 105 by Ts'ai Lun (50-118), a eunuch
attached to the Eastern Han court of the Chinese emperor Ho Ti (r. 89-105). One Chinese record
states that he " .First made paper by pulping fishing nets and rags. Later, he used the the fibres of
plants; any which proved sufficiently elastic in tension were used as the raw materials for paper.
The raw materials were first well boiled and then beaten into a mash. they were then stirred into
a pulp and spread on a straining frame or basket. When it had formed a thin tissue, the resultant
paper was then pressed with heavy weights ", although this may not be correct. It is thought that
the origins of Chinese papermaking may lie in the manufacture of bark cloth from the Pacific
Islands.
The earliest known paper still in existence was made from rags about AD 150, discovered
in Turkestan in a ruined tower of the Great Wall of China by Sir Aurel Stein in 1904, however,
there is disagreement in China as to whether some material possibly paper can be dated earlier
than AD 105.
For approximately 500 years the art of papermaking was confined to China, but in 610 it
was introduced into Japan, and into Central Asia about 750. Tradition has it that Chinese
papermakers were captured by the Arabs in a battle near Samarkand in AD 751, thus spreading
the art westwards. In 793, there was a factory working in Baghdad, with Chinese workmen
introduced by Haroun-el-Raschid. The next known place of production was Damascus, which
was to supply Europe for several centuries (particularly with the paper known as Charta
Damascena). Paper made its appearance in Egypt about 800 but was not manufactured there until
900, and from there the knowledge was taken to Morocco, and from Morocco to Europe by the
Moors.
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The fastening of papers has been historical referenced to as early as the 13th century,
when people put ribbon through parallel incisions in the upper left hand corner of pages. Later
people started to wax the ribbons to make them stronger and easier to undo and redo. This was
the way people clipped papers together for the next six hundred years.
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2.2 PAPER MACHINE - PROCESS
Pressure Screen
Flow Box
Press I
III
Calendaring Part
Pop Reel
Cutting Machine
Packing
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2.3 INDIAN PAPER INDUSTRY
Paper industry in India is the 15th largest paper industry in the world. It provides
employment to nearly 1.5 million people and contributes Rs 25 billion to the government's kitty.
The government regards the paper industry as one of the 35 high priority industries of the
country.
Paper industry is primarily dependent upon forest-based raw materials. The first paper
mill in India was set up at Sreerampur, West Bengal, in the year 1812. It was based on grasses
and jute as raw material. Large scale mechanized technology of papermaking was introduced in
India in early 1905. Since then the raw material for the paper industry underwent a number of
changes and over a period of time, besides wood and bamboo, other non-conventional raw
materials have been developed for use in the papermaking.
The Indian pulp and paper industry at present is very well developed and established.
Now, the paper industry is categorized as forest-based, agro-based and others (waste paper,
secondary fibre, bast fibers and market pulp).In 1951, there were 17 paper mills, and today there
are about 515 units engaged in the manufacture of paper and paperboards and newsprint in India.
The pulp & paper industries in India have been categorized into large-scale and small-scale.
Those paper industries, which have capacity above 24,000 tons per annum, are designated as
large-scale paper industries.
India is self-sufficient in manufacture of most varieties of paper and paperboards. Import
is confined only to certain specialty papers. To meet part of its raw material needs the industry
has to rely on imported wood pulp and waste paper. Indian paper industry has been de-licensed
under the Industries (Development & Regulation) Act, 1951 with effect from 17th July, 1997.
The interested entrepreneurs are now required to file an Industrial Entrepreneurs' Memorandum
(IEM) with the Secretariat for Industrial Assistance (SIA) for setting up a new paper unit or
substantial expansion of the existing unit in permissible locations. Foreign Direct Investment
(FDI) up to 100% is allowed on automatic route on all activities except those requiring industrial
licenses where prior governmental approval is required. Growth of paper industry in India has
been constrained due to high cost of production caused by inadequate availability and high cost
of raw materials, power cost and concentration of mills in one particular area.
Government has taken several policy measures to remove the bottlenecks of availability
of raw materials and infrastructure development. For example, to overcome short supply of raw
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materials, duty on pulp and waste paper and wood logs/chips has been reduced. The number of
trees and other vegetation cut down in order to make paper is enormous.
Paper companies insist that they plant as many new trees as they cut down.
Environmentalists contend that the new growth trees, so much younger and smaller than what
was removed, cannot replace the value of older trees. Efforts to recycle used paper (especially
newspapers) have been effective in at least partially mitigating the need for destruction of
woodlands, and recycled paper is now an important ingredient in many types of paper
production.
The chemicals used in paper manufacture, including dyes, inks, bleach, and sizing, can
also be harmful to the environment when they are released into water supplies and nearby land
after use. The industry has, sometimes with government prompting, cleared up a large amount of
pollution, and federal requirements now demand pollution free paper production. The cost of
such clean-up efforts is passed on to the consumer.
When we think of the origins of paper, our minds might wander back over 5000 years
ago to the Nile river valley in Egypt. It was there that a marsh grass called Cyperous Papyrus
flourished. The Egyptians cut thin strips from the plant's stem and softened them in the muddy
waters of the Nile. These strips were then layered in right angles to form a kind of mat. The mat
was then pounded into a thin sheet and left in the sun to dry. The resulting sheets were ideal for
writing on. Since they were also lightweight and portable they became the writing medium of
choice of Egyptians, Greeks and Romans for record keeping, spiritual texts and works of art.
It is from papyrus that the word paper comes from. Although papyrus sheets were similar
to paper in terms of function, being laminated sheets they were technically more like a mat and
therefore not the same as the papers of today. Similar processes were developed in other lands -
in Central America during the 2nd Century AD the Mayans fashioned a similar product for
bookmaking. In the Pacific Islands, a paper was made by beating a fine bark over specially
shaped logs to make clothes and ritual objects. However, none of these sheets would qualify as
true paper today.
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THE AGE OF EXPERIMENTATION
Printing technology rapidly developed and created an ever increasing demand for paper.
The early European papers were made from recycled cotton and linen - and a huge trade quickly
developed around the trading of old rags. It is said that the black plague entered England from
Europe on these old rags. Yet soon this source became insufficient and some curious attempts
were made to source new materials - the most macabre of which was the recycling of Egyptian
mummies to create wrapping paper! Others experimented with fibres such as straw, cabbage,
wasp nests and finally wood, resulted in inexpensive - and replaceable - materials for paper
making. Today, the long soft fibres of softwoods such as spruce have become the most suitable
source of pulp for mass production.
MASS PRODUCTION
The demand for paper also created the need for greater efficiency in production. In the
late 18th century the labours of Nicholas Luis Robert resulted in the creation of a machine that
could produce a seamless length of paper on an endless wire mesh with squeeze rollers at one
end. Perfected and marketed by the Fourdrinier brothers, the new machine made papers soon
replaced traditional single sheets made by hand.
Europe and America, the mass-production of paper became a thriving industry supplying
huge volumes of paper for the production of newspapers, books, magazines, paper bags, toilet
paper, money and a huge variety of other purposes - including clothing, chimney's and even
coffins! Today, the increasing volume of paper consumption has become a complex
environmental matter - and the need for new materials increasingly urgent. While recycling has
done some good, much paper is still wasted.
PAPERMAKING
The Process
Although there are many subtleties which affect the quality of a paper, papermaking in
essence is a simple process. Whether using recycled materials or fresh organic matter, the
process starts by shredding the material into small strips and soaking them overnight to loosen
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the fibres. Next, the fibres are boiled for 2-6 hours, being turned every so often. When finished,
the fibres are washed with fresh water to remove impurities and then small particles or specks are
removed by hand.
The fibres are beaten in a blender or by hand to a creamy pulp. At this stage, dyes can be
added to create coloured papers. The pulp is poured into a large tub and the fibres are suspended
in the water. The artisan dips a framed screen into the water and with great skill, lifts it to the
surface catching the fibres onto the screen. The screens can either be left in the sun to dry, or be
transferred to boards, pressed, smoothed and then dried.
Agriculture
Sacks, Seed Packets.
Building
Wallpaper, damp-proof courses, roofing, flooring, flame resistant papers,
plasterboard, and decorative laminates for furniture.
Business
Computer tapes, print-out sheets, advertisements, circulars, catalogues, filing systems,
sales and service manuals, brochures, shop-till paper.
Communication
Writing, typing, printing, envelopes, publishing, accounts, receipts, stamps, newspapers,
magazines, greeting cards, calendars, diaries, telephone directories.
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Domestic Products
Wrapping and boxes for cleaning materials, domestic tissues, paper plates and cups,
kitchen towels, table napkins, lampshades.
Education
Books, exercise books, instruction books, maps, wall-charts, report cards.
Menu cards, paper hats, crackers, fireworks, programmes, playing cards, board games,
kites, model aircraft, football coupons, race cards.
Food Packaging
Wrapping for bread, flour, tea, sugar, butter, margarine, sweets, deep frozen food etc.,
milk cartons, egg boxes, foil wrappings, tea bags, sausage skins.
Identification
Gummed labels, identity cards, tamper-proof labels for supermarkets.
Industry
Presentation, wrapping, packaging and protection for all manufactured goods, transfer
sheets for decorating chinaware.
Electrical
Special insulating boards, electrolytic condenser paper, wrapping and identification for
electrical cables, printed circuits, battery separators.
Filtration
Filters for water air, coffee, medicine, beer, oil and for mechanical uses.
Impregnated Papers
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Protective Papers
Medical
Packaging to keep instruments and equipment sterilised, bandages, plasters, clothing for
nurses, face masks, surgeons' caps, disposable bed pans, sheets, pillowcases.
Personal
Facial and toilet tissue, towels, sanitary products, tableware, sheets, disposable nappies,
confetti, carrier bags, gift wrapping.
Photographic
Films, photographs, enlargements, mounts, lens cleaners.
Legal documents, birth, marriage and death certificates, wills, history, scientific data.
Travel
Tickets, passports, maps, charts, luggage labels, timetables, fibre for suitcases.
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CHAPTER – III
ORGANISATION PROFILE
GVG Paper Mills Private Limited was Incorporated In the year 1985 as a private
limited company with an installed capacity of 3000 Meter tons annum of printing and writing
paper.
The company commenced its production in the year 1986with a capacity of 10 Meter tons
per day and within a span of five years, the production was increased to 20 Meter tons per day
with the installation of 1991, the company went in for machine general machine to produce
Kraft varieties of paper with a capacity of 15 meter tons per day. This has enabled the company
to have a wide range was converted as a dedicated New a print.
During the year 1995-96, the company put up the year 1995-96, the company put up the
third machine (machine general ) to manufacture special varieties of paper. The present capacity
of the Mill is 140 meter tons /Day and the turnover is around Rs.115.00Crores per annum.
The company exports around Rs.15.00 Corers/annul and imports around Rs.12.00
Corers/Annum. GVG group has paper mills and third textile mills with a combined turnover of
Rs.275.00 Corers per annum. The production capacity of two paper mills is 200 meter tons/Day
and the installed capacity of textile mills is 65000 spindles.
The company has working capital limits with m/s the lakshmi vilas bank limited
udumalpet with a fund based limit of 10 crores and non-fund limit of 5.5 crores
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3.2 PROFILE OF THE FIRM
Directors : Sri.M.Velusamy
Sri .M.A.Padma,
Employees : 750
Male : 400
Female : 350
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3.3 VISION AND MISSION THE COMPANY
MISSION:
VISION:
Always exploring ways to further the quality and maintain consistency of the product.
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3.4 ORGANIZATION CHART
Managing
Director
General
Manager
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CHAPTER - IV
In GVG Paper Mills Private Limited there are various functional departments which
performs different functions they are;
Purchase department
Production department
Sales department
Finance department
The purchasing department is responsible for providing the materials, components and
equipments required to keep the production process running smoothly. A vital aspect of this role
is ensuring stocks arrive on time and to the right quality.
Purchase means “to obtain ownership of a security or others asset in exchange for money
or value”.
The main aim of the purchase department is to buy good quality raw materials, which is
used to produce good quality paper .Raw materials are purchased from local suppliers and it’s
also imported from countries like Egypt, US, Srilanka, and European countries.
The company purchases the raw materials through agents. The price is quoted and given
to the local agents and they purchase the raw materials according to it. Local vendors are from
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Coimbatore, Thirupur, Trichy, Salem, & Kerala. They purchase raw materials mainly from
kerala. The raw materials are transported from vendors to the company by using their own lorry
service or by the services of private transport agents.
For importing the raw materials they have some agents, the agents who are authorized by
the central government. They import the raw materials from US, Srilanka ,Egypt, Australia and
European countries most imports are through the agents, the agents procure the raw materials
according to the Intimation given.
The company provides procurement form to it agents which contains the details like,
Mode of transportation
Agent name
This procurement details are sent to the port authorities (custom officer), agent to the
bank (Lakhsmi Vilas Bank, Udumalpet, branch) and to the government
Letter of credit
Transportation cost
Substitution
IE code
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Shipping bill
Bill of lading
These are the functions performed by the purchase department of GVG Paper Mills
Private Limited
The production department set standards and targets for each section of the production
process. The quantity and quality of products coming out of production line are closely
monitored. In businesses focusing on lean production, quality is monitored by all employees at
every stage of production rather than at the end as is case for businesses using a quality control
approach.
The main aim of the production department is to give good quality paper. In this
company they are producing three kinds of paper. They are,
Kraft paper
This kind of paper is used in note book and other writing, printing purpose. This firm
produces the paper by recycling the used papers. The raw material used in this kind is
note book papers and examination papers etc…
For good grade of writing paper they are using 60% to 70% local raw materials and 30%
to 40% of imported raw materials.
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Production process
The raw materials taken by the chain conveyer to the icon pulp chamber.
Icon pulp is nothing but the mixie it makes the raw materials in to clay state
And it is taken into bimbo pulper (6mm) which bleaches the used paper by using the
NaOCl2 bleach liquor like Cl2 which bleaches the paper clearly.
Blade named impeller which is used to make raw material in to liquid state.
Liquid state is flowed in the synthetic cloth which sucks the water out.
And it is under goes 3 processes by 8-4-2 cylinders which makes the paper rough by
leaving enormous heat.
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Process
Raw
Conveyer
Materials
Bimbo
Iconpulper
pulper
Chester Synthetic
Champer Cloth
Cutting Package
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Kraft paper
In this variety local raw materials are used and coloring agents are added to get different
colours of Kraft paper. Same production processes (M.G.Machines) are under gone for this
variety of paper also. The coloring agents are added when the pulp in the Chester chamber. The
coloring agents used are,
Methane green
Methane violet
Methelene blue
Rhodaminie
In this variety of paper news paper, are used as raw materials there is no additional raw
material used. They sent this paper as rolls.
Stores
The stores is under the control of production department. Employee in the production
department works in store department.
Maintenance
Chief electrical engineer looks after the electrical works in the concern for the regular
flow of production.
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Go down:
After the finished product is packed they are shifted to go down and the ledger is
maintained by the go down keeper.
The sales department will seek to make sure that the company has a marketing focus in
everything that it does. It will work very closely with production to make sure that new and
existing product development is tied in closely with the needs and expectations of customers.
A useful definition of sales is the anticipation and identification of customer needs and
requirements so as to be able to meet them, make profit and achieve other key organizational
objectives
The main aim of sales department is to market the products in a well versed manner.
Functions undergone by the sales department are;
Functions
The agents helps the company to market their product in foreign countries.
They find the market through their agents.
Sales are made based on the orders received.
Company gives their agent offers and some schemes for finding good orders.
The company gives no advertisements.
The agent acts as a indirect sales representative
The exports are done according to procedures laid by the central government
Goods are exported through ships
Lorries are used for moving the goods from the company to the ports.
They export goods from Tuticorin, Chennai ports
To increase their standards they are investing 5 crore every year for their overall
development. Daily sales are reported to the head office. Srilanka and Egypt are the main
importers.
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4.4 HUMAN RESOURCES DEPARTMENT
Human resources are the people that work for an organization, and Human Resource
Management is concerned with how these people are managed. However, the term Human
Resource Management (HRM) has come to mean more than this because people are different
from the other resources that work for an organization. People have thoughts and feelings,
aspirations and needs. The term HRM has thus come to refer to an approach, which takes into
account both
Human resources department main work is to give good working condition to the worker.
There are 250 workers and 500 indirect workers in factory and 25 staff members in the office
Type of workers
There are two types of workers they are skilled workers and semi skilled workers.
Shift
Workers shifts are changed once in a week. There is a shift in charge in maintaining
changes to be made in the shift.
Timekeeping
Through Time card system employees worked time is calculated. Each employees are
given time card.
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Wages
The monthly wage bill of Rs 15 lakhs is paid every month. Daily wages given are;
Leave
Once in 20 days leave is given to the workers on a rotation basis. Leave for workers are
given on special occasions like May 1, ayodha pooja, deepavali, etc…if the company is on leave
they give one day salary.
Bonus
Office
25 members are working in the office of GVG Paper Mills Private Limited these
employees are permanent.
Working hours
In GVG Paper Mills Private Limited working time starts from morning 9am to evening
4pm
Salary system
Basic 60%
FDA-22%
Others-18%
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Leave
Special occasions and every Sunday’s are holiday for office members.
Bonus
The company gives 12.5%as bonus for office members. These are the system under gone
in the human resources department of the company.
The finance department of a business takes responsibility for organizing the financial and
accounting affairs including the preparation and presentation of appropriate accounts, and the
provision of financial information managers.
Finance means
The main work of this section is to record the transactions receipts and payments done
through bank.
Financial statements are prepared under historical cost convention on accrual basis of
account. Everyday business transactions are recorded and kept for reference which is referred by
the head of the department.
The company has working capital limit to 8.5 crores. Where Lakshmi Vilas bank
Udumalpet branch provides 6 crores out of 8.5 crores and the company has made 2.5crores as it
share. journal is prepared for the every transactions and then it transferred to the ledger
They are recording the accounts by using computers and also by manual process.
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Cash book
In this book only the cash transactions are recorded .The amounts received are bettered in
the cash book daily by preparing cash receipts and bank receipts.
Bank book
All the transactions done by the bank are recorded in this book.
Purchase book
Sales book
Debtor note
Customer transaction and dealer transaction are recorded in the debtor part.
Creditor note
Purchasing agents’ transactions are recorded in the creditor part.In this debtor and
creditor various accounts such as bank account, income to the company expenses done are
recorded and maintained.
Journal book
In this adjustment entries are recorded debit note, credit note details are maintained in
this book.
The company pays an amount of Rs3.50 crore per annum by way of excise duty Rs.3.00
crore by way of sales tax and Rs75 lakhs by way of income to every year and have paid an
advance tax of Rs1.00 crore this year. The company is investing Rs5 crore to improve its
standard.
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4.6 QUALITY CONTROL DEPARTMENT
Steps are taken to make sure that a company’s products and services are of sufficiently
high quality.
This department checks the quality of papers and gives the results to the production
department
They are undergoing several tests for determining the quality of papers. They are,
Functions
The production department follows the mixing ratios, intimated by the quality control
department.
Before going for bulk production they test the samples, based on the results they go
for follow up actions.
Quality control department play dominant role in buying the raw materials.
Chemicals used for Kraft papers are purchased according to their advice.
Instruments used
Mercury lights are used for determine the colors of the paper.
These are the functions performed by the quality control department of GVG Paper Mills
Private Limited .
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CHAPTER – V
WORK DONE
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CHAPTER – VI
CONCLUSION
This unit from its inception is running at profit. This has handled many welfare measures
to their employees.
GVG PAPER MILLS PRIVATE LIMITED is well directed and managed by the
managing director. The company has framed clear-cut policies objectives, procedures and
guidelines for the workers to carryout smooth functioning of the concern.
This industrial training has left me with sufficient knowledge about the working systems,
procedures and functioning of the industry.
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