Presentation of spmcil indigenization of banknote paper production

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2. The present requirement of India is about 25,000 MT per annum and is mostly met by imports. A security paper mill was set up by Govt of India in 1967 at Hoshangabad to manufacture various security papers including banknote paper. As the paper mill is very old and mostly engaged in manufacture of other security papers, the mill is able to meet only around 5% of present requirement. MOF, GOI decided to set up 3 State-of-Art production lines for manufacture of banknote paper, two lines at Mysore in a green field environment and one line at existing security paper mill, SPM, Hoshangabad as expansion. The planned capacity of the green field project at Mysore is 12,000 TPA and that of SPM Hoshangabad is 6000 TPA. Powerpoint Templates2 3. The state of art machinery with highly advanced technology will be a new milestone in the history of Indian currency. As the both the projects are going on at different locations two separate presentations are envisaged, one for the Green Field Project at Mysore and another for expansion of security paper mill at SPM, Hoshangabad. This presentation is about Green Field Project, Bank Note Paper Mill India Private Limited (BNPM). Powerpoint Templates3 4. The 50:50 JV Company between SPMCIL and BRBNMPL was incorporated on 13th October 2010, Bank Note Paper Mill India Private Limited (BNPM) with its Corporate office at Bangalore and the Paper Mill at Mysore. 2 State-of-Art production lines have been planned for manufacture of 12,000 TPA banknote paper, at Mysore by incorporating and establishing a new JV Company. The scope of main paper machine supplier includes design as per the specification and requirement of banknote paper, manufacture, supply, install, commission, trial production and training of staff for regular operation and maintenance. BNPM will be an integrated paper mill with sections of manufacturing; Pulping and bleaching, Stock preparation, Paper making, Sheeting & packing and an exclusive section Powerpoint Templates 4 Mould cover manufacture shop. 5. The most of the special type of machinery are imported from Germany, designed and manufactured as per the specification and requirement of banknote paper. State of art machinery has been chosen with latest available technology with the ambition of making the paper mill, the best in the world. All the utility services have been sourced from India. There are around 30 such packages. The present estimated cost of the project is around Rs 1500 Cr. and the commissioning of the 1st line is expected around end of Dec 2014. Powerpoint Templates5 6. The innovative decision of MOF, Govt. of India to develop capability in India for the manufacture of banknote paper indigenously without a JV partner from abroad, in contravention with the opinion of some experts in the field. Setting up of a Green Field Project as a Special Purpose Vehicle of Govt. of India by establishing a JV Company, Bank note Paper Mill India Private Limited (BNPM), by both the user companies, SPMCIL and BRBNMPL, and adopt & inculcate world class work practices & culture and produce banknote paper of international quality. Procurement of the special purpose machinery through global tendering process as per our specification to suit incorporation of security features of Indian banknote. Powerpoint Templates6 7. Transfer of latest technology and latest process without a technology partner. Acquiring the knowledge and skill required for regular operation and maintenance of most advanced and automated paper machines through OEM. Getting the automated banknote paper mill machinery with specially designed DCS and QCS and integrating with continuous special purpose pulping system. Procurement of highly automated mould cover shop, to overcome difficulties faced by the present paper makers. Procurement of automated, special purpose sheeting system with registered cutting, automatic inspection and quality control. Powerpoint Templates7 8. Implementing automatic material handling system. - The automatic raw material feeding from raw material yard to fully automatic continuous bleaching and pulping section. - Automatic feeding of the trims to the pulper. Incorporation of online inspection by using cameras, sensors and other feedback systems at various stages of manufacture of paper to minimize the rejection and increase overall efficiency. Designing, procuring and implementing sophisticated security surveillance, operator surveillance system and access control system to ensure safety and security of the entire plant. Powerpoint Templates8 9. Designing, procuring and implementing advanced effluent treatment cum recycling plant to make the Paper Mill totally environmental friendly. Making a Zero discharge Paper Mill, probably first time in the country and in the world in similar industries. Designing, procuring and implementing other 30 utility packages and systems, all indigenously, as per the requirement of main machine and process and integrating the same to main DCS supplied by the paper machine supplier. Making a world class R&D Laboratory for future innovations. Powerpoint Templates9 10. Effective utilization of the land for a green field project. Only around 35 acres of land will be used for two lines of paper machine to produce 12,000TPA banknote paper, probably one of the lowest in the world. World class automation and optimum utilization of human resources. Planned to employ only around 350 staff for regular operation and maintenance of TWO lines in 24x7 basis for the green field paper mill. Set optimum time target to set up a green field banknote paper mill after incorporating a new JV Company. Procuring, installing and commissioning highly automated special purpose machine through global tendering in only around 4 years. Powerpoint Templates10 11. Targeted highly competitive cost for the manufacture of banknote paper. Expected cost per Ton of paper produced will be around Rs 7.0 L as against Rs 9.0 L (Import cost) for the comparable grade. Targeted to establish the production at higher level of machine speed (80-90 M/Min) compared to international average speed of similar machines (around 60-70 m/min). Use of special continuous bleaching process to minimize use of chemicals for bleaching and pulping process. Planned to minimize use of raw material by maximizing the recycling of rejects. Powerpoint Templates11 12. Minimum use of natural resources. Water consumption planned is less than 75 m3 per Ton of paper produced. Planned for maximum recycling of water by the use of special filtration plant and advanced effluent treatment system. Planned to recover maximum secondary fibres from the effluent before sending the same to effluent treatment plant by the use of special type of fibre recovery system and this will make the total plant more environmental friendly. Planned for maximum use of energy efficient systems. Adoption of VFDs, use of energy efficient and solar illumination systems, heat recovery systems, etc. Powerpoint Templates12 13. Indigenization of banknote paper production will avoid dependency on foreign country. Indigenization of banknote paper production will ensure security of sovereign product. In war like situation, or due to imposition of sanctions like that happened in Iran, indigenization of banknote paper production will avoid facing serious difficulties for maintaining a sovereign function, printing of banknotes. Production of indigenous banknote paper will help to control counterfeiting and it is one of the major anticounterfeiting measure. Usage of 100% Indian raw material will make our banknote paper a unique sovereign product. Powerpoint Templates13 14. Economic benefit to the society due to usage of locally grown raw material, Cotton. Direct and indirect employment generation Local area development through CSR activities Big savings in foreign exchange, every year. All the three lines are expected to manufacture 18000 MT of banknote paper per annum on attaining its full capacity. Present annual import cost for 18000 Ton of banknote paper is about 165 Million Euro which is slightly higher than the total cost of imported machinery for three lines of paper production including that of SPM Hoshangabad to produce 18000 Ton of paper. Powerpoint Templates14 15. Indigenous production of banknote paper will also help to increase the revenue for state and central Govt departments, in the form of various taxes applicable for the procurement of raw material and on the sale of product. This project will provide lot of flexibility to banknote printing presses owned by SPMCIL and BRBNMPL for the procurement of banknote paper of different denominations as per the required denomination mix and delivery schedule. Indigenous paper production will also improve supply chain efficiency and reduce the inventory cost of printing presses and in turn reduce the cost of banknote printing. Participating in the Nation building exercise - Big boost in morale of the people. Powerpoint Templates15 16. India is the second 2nd largest consumer for banknote paper in the world and the demand of currency is increasing day by day. The annual requirement of the banknote paper has increased from 13,500 MT in the year 2007 to 25000 MT in the year 2013, almost 85% increase during the last 6 years. The statistics reveals that, our country will have to increase the manufacturing capacity of banknote paper immediately after establishing the new projects to meet our own demand. By establishing this project our engineers and technicians will acquire the required knowledge and master the skill to meet with all future challenges in Powerpoint Templates the field of banknote paper manufacture.16 17. Indian banknote paper still uses security features developed by other countries. This project will give an excellent opening for all Indian R&D organizations like CSIR Laboratories to