Developing paper based on bagasse to map forth a sustainable future

Tamil Nadu Newsprint & Paper Limited (TNPL) epitomizes the fusion of innovation with sustainability, excellence, and unwavering dedication. This integrated pulp and paper enterprise holds a distinctive edge in overseeing the entire gamut of paper production, from plantation to the final iterations of paper and paperboards.

Distinguished as India’s inaugural bagasse-based paper mill, TNPL takes immense pride in churning out 400,000 metric tonnes (MT) of paper annually, catering to a clientele spanning over 60 nations. Positioned at the zenith as the foremost producer of writing and printing paper domestically and among the globe’s preeminent bagasse-exploiting paper mills, TNPL is steadfastly committed to a monumental objective—achieving the production milestone of one million tonnes of paper by 2030.

Founded in 1985, TNPL Unit I commenced operations with a capacity of 90,000 tonnes per annum (TPA) of newsprint and fine paper. Presently, bolstered by cutting-edge automation, the unit churns out over 400,000 TPA, cementing TNPL’s eminence as a global frontrunner in bagasse-centric paper manufacturing. In its quest for global preeminence, TNPL conceived Unit II, a paperboard venture brought to fruition within a mere 18 months.

Encompassing a sprawling expanse of 874 acres, Unit II nestled in Mondipatti, Trichy district, yields 200,000 MT of premium-grade paperboard annually. Striving for absolute sustainability and waste-free manufacturing, TNPL inaugurated a cement plant in 2013, harnessing solid waste from the paper mill. Commencing at 600 tonnes per day (TPD), it presently fabricates top-tier cement at a capacity of 900 TPD.

Strategically situated proximate to a port, the company reaps logistical advantages in the seamless importation of raw materials and exportation of finished goods. Equipped with state-of-the-art machinery, TNPL stands at the vanguard of paper and paperboard manufacturing in India. The distinctive pulping process amalgamates a melange of wood, bagasse, and deinked pulp (DIP), underscoring its commitment to environmental stewardship and resource optimization.

The company’s workforce, distinguished by its exemplary training and unwavering dedication, mirrors TNPL’s ethos of fostering employee development and satisfaction. Governed by an autonomous cadre of technocrats and helmed by a visionary Chairman & Managing Director (CMD), TNPL ensures excellence in governance and strategic leadership. Embracing industry-leading practices worldwide, the company endeavors to establish its own benchmark, delivering products of unparalleled quality. TNPL endeavors to ascend as the paragon of sustainability in paper and paperboard manufacturing globally, leveraging cutting-edge technology, crafting eco-friendly products, and nurturing an all-encompassing work milieu. Aspiring to be acclaimed as the epitome of workplace excellence, TNPL seizes growth prospects within the industry.

Dr. M Saikumar, IAS, Chairman and Managing Director of TNPL, asserts, “A prized asset in the Tamil Nadu government’s arsenal, TNPL stands as a vanguard within the industry, deploying novel technologies in an environmentally sustainable manner to meet global benchmarks.”

Dedicated to quality
With incessant upgrades and innovations, TNPL’s production capacity has surged from 90,000 TPA to 600,000 TPA to date. Introducing groundbreaking technology to curtail steam consumption and ensure uniform pulp quality, the company installed a 300 TPD deinked pulp line with 3 Loop 2 disperser configuration and a two-stage bleaching process to yield PWP-grade deinked pulp.

Functionality trials were conducted to ascertain the efficacy and performance of chemicals. Optimization of pulp furnishings, coating formulations, and chemical additives facilitated substantial cost savings. Trials with nano-binders were undertaken to slash binder costs without compromising functionality.

Advocating sustainability
At TNPL, sustainability transcends mere aspiration; it’s a blueprint for shaping the future. The company embarks on a trajectory toward excellence and environmental stewardship. Renowned for its environmental consciousness and eco-friendliness nationwide, TNPL boasts minimal water consumption. Wastewater generated at the mill is treated via the company’s advanced water treatment plant and repurposed as process water, serving irrigation purposes as well.

Utilizing a million tonnes of bagasse, a renewable byproduct of sugarcane, TNPL circumvents the exploitation of approximately 30,000 acres of forest land for commercial purposes. The company strives to reduce energy consumption at its Effluent Treatment Plant (ETP) by 2000 units per day. Successful trials have been conducted with polylactic acid extrusion coating to replace PE coating, alongside Online Barrier Coating trials, both certified for compostability by CIPET, Kochi. TNPL boasts FSC-FM and FSC-CoC certified captive plantation and farm forestry for pulpwood, a vital raw material for paper and packaging boards.