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Karanja Industries (Pvt.) Ltd.Karanja Industries (Pvt.) Ltd.

PROMOTERS PROFILE/ COMPANY PROFILE:

INDUSTRY PROFILE

Paper Industry is riding on a strong demand and on an expanding mood to meet the

projected demand of 8 million tons by 2011 & 13 million tons by 2020 according to India.

The Indian Paper Industry is among the top 15 global players today, with an output of more

than 6 million tons annually with an estimated turnover of Rs.1,50,000 million.

A large number of expansion program & expansion of capacities with an outlay of

Rs. 10,000 crores have been announced covering the various sectors like paper, paperboard,

newsprint.

The Indian Economy is progressing well and targeting 8%+ growth. The economic

reforms coupled with the liberalized Government Policies, India today offers excellent

business opportunity for investments.

One of the first FDI Projects may come through the proposed Finish proposal to set

up a 4, 00,000 TPA capacity plant with an investment of US$240million.

The expanding Industrial Scenario calls for efforts to tackle related problems:

Industry needs capital and technology.

Since energy cost accounts nearly 25 per cent of cost of production there is an

urgency to improve energy management and energy consumption.

Quantum jump in production, called for by the demand projection is possible only by

expansion of existing capacity and creation of additional capability. Up gradation oftechnology and new capacities also involve massive investment.

Use of agro residues for preparation of pulp also throws up challenges like pollution

control, recycling, use of cost effective technology for utilization of agro residues,

etc.

ADMINISTRITIVE MANAGEMENT COLLEGE BANGLOREADMINISTRITIVE MANAGEMENT COLLEGE BANGLORE1


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Paper Industry in India

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 Srirampur, 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,

best fibres 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 tonnes 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 rayon imported wood pulp and wastepaper.

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



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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 materials, duty on pulp and waste paper and

wood logs/chips has been reduced.

Following measures need to be taken to make Indian paper industry more competitive:

Improvements of key ports, roads and railways and communication facilities.

Revision of forest policy is required for wood based paper industry so that plantation

can be raised by industry, cooperatives of farmers, and state government. Degraded

forest land should be made available to the industry for raising plantations.

Import duty on waste paper should be reduced.

Duty free imports of new & second hand machinery/equipment should be allowed for

technology up gradation.



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COMPANY PROFILE

In the year 1983, the Karanja Industries Pvt Ltd. started its operation in Bidar

district. Due to Backward area the government had given the subsidy to start its operations

for developing this area. And the company had seen the availability of the raw material,

transportation, market opportunities, cheap labor and well water resource etc.

The Karanja Paper Industry was incorporated during the year of 1983 with

authorized capital of Rs. 5,00,000/- under companies Act 1956 for manufacturing of white

cutting duplex board with a capacity of 3000 tons per annum.

After identifying the viable location the company could acquire the land of 36

acres. The company secured loans of Rs. 1.6 crores from various financial institutions during

1986 and put the plant on the stream during September 1988 with the project cost of Rs. 234

lakhs. From 1st November 1988 it has resumed the commercial production.

While on 30

th

November 1996 the Karanja Industry had received I. S. O. 9002certificate by STQC Directorate Government of India New Delhi.

After this they are decided for 50 ton capacity paper mill and this dream was

completed in 2001, This paper use for packaging of various material, Which paper known as

a Kraft paper.



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PRODUCT PROFILE: -

The company manufactures mainly two types of paper products. One is White

Duplex board and another is Kraft Paper.

The raw material required mainly is only all types of old paper and

imported. The required papers are brought from local and outside places like Maharashtra,

Kerala, and Karnatakas various cities and America, Saudi imported. The raw material is

brought from the entire place through road and rail.

. .



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Kraft papers



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Duplex Board

NATURE OF THE BUSINESS CARRIED:

The company manufactures mainly two types of paper products. One is White Duplex

board and another is Kraft Paper.

The raw material requires mainly is only all types of scrap paper. The required papers

are brought from local and outside places like America and Saudi, Maharastra, Kerala, and



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Karnatakas various cities. The raw material is brought from the entire place through road

and rail.

VISION, MISSION AND QUALITY OBJECTIVES:

VISION:-

Aim to increase the production by 65 tones per day by 2009

Planning to have ISO 14000 certification for environmental management by 2012.

Planning for introduce the LWC (Light Weight Coating) HWC (Heavy Weight

Coating) system to the existing product by 2012.

LWC Light Weight Coating upto to 10 gm / cm2

HWC (Heavy Weight Coating) means to provide upto 25 gm / cm2 of thin layer of

chemical coating.

MISSION:-

Karanja Industries (P) Ltd. is following the quality policy which clearly depicts

the type of product and service characteristics provided by them.

Shall strive to provide quality product and services at competitive price, to satisfy the

requirements of the customers.

Shall encourage new ideas and efforts from all levels for continuous improvement.

QUALITY OBJECTIVES :-

Developing at least 2 new customers a year.

To achieve 5000 tons of Duplex Board and 3000 tons of Reclaimed Rubber and

14400 kraft paper.

The Management will reconstruct the objectives in every Management Review

Meeting as applicable depending upon the requirement.



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AREA OF OPERATION: (National/Regional):

The area of operation of the Karanja Industries Pvt Ltd is National and Regional

level only. Karanja Industries (Pvt) Ltd. has wide distribution network. The Company

increased the number of dealers to push the product into the market.

The following are the few dealers to whom Karanja Industries (P) Ltd. is selling their

products white Duplex Board/Kraft paper.

OWNERSHIP PATTERN:

This company is owned by 46 shareholders but out of these only seven are active

shareholders.

The active shareholders are as follows:-

SRI. JAGAN LACHUREY CHAIRMAN

SRI B.S KUDRE MANAGING DIRECTOR



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SRI. H.S BIRADAR DIRECTOR

SRI. V.S. CHILLARGI EXECUTIVE DIRECTOR

SRI. VIJAYKUMAR PATIL EXECUTIVE DIRECTOR

SRI. PANDURANG BIRADAR DIRECTOR

SRI. SHARANAPPA PATIL DIRECTOR

COMPETITORS:

Gramox Paper Kerala Duplex Board.

Sarvalakshmi Papers Tamil Nadu Duplex Board.

Murli Agro Papers Nagpur Duplex.

Bedse Paper Mill Aurangabad Kraft paper.

Awade Paper Mill, Sangli Kraft paper.

Vijayanand Papers Andra Pradesh

Local Competitors:-

Gemini Graphics Industries Pvt Ltd. Bidar.

Veerji Paper Mill Pvt Ltd- Bidar.

The competitors watch each other carefully and formulate the strategies to increase their

dealers.

ACHIEVEMENT / AWARDS:

The following achievements are achieved by the company in its life time.

The company received on Award for Excellence for an excellent performance of

the company by KSFC during 1994-95.

While on 30th November, 1996 the company added one more diamond to its crown.

The company received ISO: 9002 certificate by STQC Directorate Govt. of India,

New Delhi.



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On march 2003 the company has switched over to ISO: 9001-2000 version which is

in upgraded version

Further in appreciation of the excellent performance of the company. The M/s

KSIDC Bangalore allotted Excellent Track Record AAA for best performances andalso allotted the Health Code No. 1 for working capital operator limit efficiency by

Canara bank.

In addition to the above achievements the following awards were conferred on the

M.D. of the company for excellent performance.

Award for excellence by KSFC Bangalore.

Vijayshree by International Friendship Society of India, New Delhi.

Udyog Excellence Award by Industrial Economic Forum Mumbai.

Bharat Gaurav Award by Council for National Develop, New Delhi.

Indira Gandhi: Priyadarshini Award by All India National Unity Conference

New Delhi.

Bharat Udyog Ratana Award by Indian Economic Development and

Research Association New Delhi.

Industrial Excellence Award by Industrial Exhibition Committee, New

Delhi.

Rastriya Nirman Award and national Goldstar Award by Forum for 21 st

century Development, New Delhi.

Rajeev Gandhi Shiromani by Global Economic Council, New Delhi.

FUTURE GROWTH AND PROSPECTS:

To open a school for companies workers children.

To open a hospital in factory campus.

To provide colony facilities to the workers.

To expend the market area to U. P., Kolkata, Delhi, etc., i.e., through out

North India. To provide better quality of product at cheapest rate.



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Effected treatment plant: The industry having good water management to

reuse or recycle the waste water within the system it self having a good E.T.P.

Company plan is to increase production by 10 to 15 MT modification in

production unit. They are supplies their product to I.T.C and pass India ltd. They try to get

more and more supply with quality and quantity to customers.

ORGANIZATIONAL STRUCTURE

Managing Director



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General Manager

Factory Manager Paper Division

Asst. Stores Mgr Time Office In charge Q.A.I/CProduction

Manager

Store Asst AsstLab

Asst

R/M

Insp

Finishing

SuprETP I/C

Elect Supr Maint

Engg.

Shift

I/Ss

Pulp

Mill I/C

Finishers Operators Electricians Fitters Opts Opts

FUNCTIONAL AREAS

HUMAN RESOURCE DEPARTMANT

MANAGER

ASSISTANT MANAGER SUPERVISOR



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Human resources management involves recruiting and addressing staffing

needs, hiring and training the best employees and making sure that these employees turn out

to be out standing performers. It also includes dealing with performance issues and ensuringemployees personnel and management practices conforms to various regulations.

Any organization with manpower as its chief capital is a treasure of talent. It is the

HR department which acts as the key to unlock, identify, develop and utilize employee skills

and talents to further individual as well as organizational goals. The chief functions of the

HR department Training and Development change the management, salary and benefits,

industrial and employee relations and performance appraisal.

The HRM department here at Karanja Industries Pvt.Ltd consideration the employee the

foremost and major resources of the company upliftment of employees growth are at the

center of organization philosophy of growth, which aims at providing a career in which the

individual can make at the same time better standard.

The role of the personnel management is an organization is a more valuable to

achieve the organizations goals. The Personal Department will conduct the advanced

technical training to develop the employees skills at the works.

Functions:-

1. Personnel Department provides a set of techniques for handling people with

professional standard.

2. Personnel Department helps the employee to utilize their capacities to the maximum

level and to attain not only individual satisfaction but also satisfaction as a part of the

work group.



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3. Manpower planning.

4. Recruitment and Selection.

5. Introduction of the newly recruited employee.

6. Training and development of the employee.

7. Motivation/Counseling.

8. Grievance handling.

9. In time communication to the employee.

10. Promotion.

11. Discipline & disciplinary actions.

12. Health, safety, welfare of the employee.

Apart from the above functions, the personnel department also liaison with various

statutory bodies like Labour department, Factory Inspectorate department, P.F. Office etc., It

is the responsibility of the department to prepare the statutory returns falls under various acts

and submit the same to the concerned authority within the stipulated time.

RECRUITMENT:

Recruitment is the process of stimulating the prospective candidates to apply the job.

Karanja Industries Pvt. Ltd uses the following sources to recruit the candidates. :

Advertisement in news paper & electronic media.

Walk in interviews

Promotion is totally based on working experience of the employees. Company believes in

promoting those employees who really contributes towards the growth of the organization.



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SELECTION PROCESS

First the applications were received, then the candidates are scrutinized, then they

send call letter to the candidates, then the interview is taken by Head of the Department

takes the interview & induction will be done for selected candidates. At every stage

scrutinizing is there.

TRAINING AND DEVELOPMENT

Company is also conducting exit interviews of separating employees by the head of

HRM the out come of the exit interview is discussed in top-level meetings in order to keep

pace with change due to the liberalization and globalization initiated steps are taken to

upgrade the skill of the employee train them periodically, internally and if required through

external programs 95% of management at staff is computer literates.

INFRASTRACTURAL FACILITIES:

The company has provided the infrastructure like building, workspace, process

equipments, computers and supporting service (transport or communication etc.,) for meeting

their equipments of the customer.

PRIVIDEND FUND AND GROUP INSURANCE:Under this benefit, monthly deductions from the employees salary are made. The

employer contributes an equivalent amount. At the time of retirement, death the full balance

of his / her credit with interest is payable. And the company also provides group insurance to

their employees.



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WAGES SYSTEM

Time wage system / Fixed wage system is practiced in the organization because

measurement of each employees outputs are very difficult.

CANTEEN

The company is having a canteen in the factory campus only supplying the food at

cheapest rate than outside, to the workers of the company.

MEDICAL TREATMENT

The company providing medical allowances about doctor fees and medical

expenditure whatever paid by the worker. If the injured at the working hours all the expenses

incurred are paid by the company and some extra allowances with half salary up to his injury

period are paid.

TRAINING FACILITY

If some workers show some extraordinary service then for his further improvement

the company may send them for training. Company gives On the Job and Off the Job

training. Company sends them for attend the national level and state level seminar for

managers only.

SICK ROOMS

The sick room facility is providing here to the workers during their leave hours and the

sick room for visitors also available.



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BONUS

The company is providing Bonus to employees is 8.33% based on workers salary.

Promotion facilities available in this company.

GOOD VENTILATION, LIGHTING

For better environment conditions to the workers in the factory good ventilation and

soft lighting are used to maintain the workers health in the production area.

UNIFORM, SHOES, HELMETS

For every worker working permanently in the company could get factory uniforms,shoes, helmets and safety measures every year.

PARKING FACILITY

The parking facility is provided for the employees cycles, two wheelers and

four wheelers and for the trucks which bring the raw material.

ACCOUNTS DEPARTMENT

ACCOUNT MANAGER

ASSI.A/C MANAGER

SUPERVISOR



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CASHIER

The accounts are maintained in the double entry system of book

keeping. The basic documentation is done through chequs, vouchers, receipts, bill invoice

and journal voucher.

The accounts department is headed by internal auditor of the company. All the

accounts are computerized. Tally accounting software is in use.

The total expenditure of the company of Rs.3 crores per month. The total monthly

salary of workers of Rs.16 lakhs.

The company maintains a clean and perfect Accounting system. The main

activity of the Account Department is Working Capital Management. Preparation of

financial statements such as Balance Sheet, Profit & Loss Account etc is also the

activities of the Finance Department. Secretarial works relating to Board comes under

the review of this Department. Most of the activities carried out by the Account

Department pertaining to long-term and short-term requirement of the operation using

Purchase Bill maintaining the accounts of contractors, sub-contractors, Income Tax

deductions, salary, discrepancy, dealing with the financial institutions with imports andexports are also the functions of the Account Department.

Functions of Account Department:

1. Funding Activity

Banks provide both long-term and short-term funds.

Long-term funds like debentures, term loans, etc are used for project financing.

Short-term loans are taken to meet the working capital requirement.

Commercial banks help in providing short term funds.



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The account department will be having the continuous communication with the head

office, so that the corporate office can transfer the funds to its unit. This is called as Fund

transfer booking.

2. Treasury Function

They will maintain cash or bank balance book for any payment. They will use only

cheques for making transactions.

3. Book Keeping

A company should maintain books of accounts. There is an own built computerized

system including the accounts of sale, purchase, cash/bank, stock, tax, fixed assets, etc.

The department has to disclose the information by closing the books monthly. The

books disclose the information to the share holders of the company.

PRODUCTION DEPARTMENT

The production department is headed by the production manager. The function of

the production department is to produce our products on time, to the required quality levels,

at the defined product cost. Of major concern to the production manager is monthly output.

Production managers have monthly targets which they are expected to strive to meet orexceed.

Production can only meet its targets if Sales secure orders. Also production costs are

dependent on the price we pay for components and materials etc.



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Four important sections of the Production Department.

WATERMAN LINEMEN ENGEENEAR STORKEEPER

ETP SECTION :

Effluent water is treated in ETP Plant waste water takes birth in pulping and

dehydration process and washing activities is plant treatment and recycling of water for it

taken to ETP (Effluent Treatment Plant). ETP contains considerable amount of waste

impurities like pins, dust etc. They were neutralized by using lime water, alum and sulphuric

acid after sterilization of the mixed material, the impurities will be drained and fresh water

will be utilized in recycling of puling process.

TREATMENT OF WASTE MATERIAL :


PRODUCTION

MANAGER

Electrical SectionETP Section Mechanical Section Process Sections


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The main advantage of the company is 100% use of waste material because the basic raw

material used is any kind of papers thus waste paper in various processes, cut downs, on

sized papers, defective quality of papers all are reused, they were stored at one place and

passed to pulp mill were they used for pulping process and water which is waste again reused

by purifying then at ETP Plant.

ELECTRICAL SECTION:

There is one supervisor and 4 electricians working, 3 electricians in 3 shifts all the

electrical work is done by this department. Any power on / off power supply, wiring,

lighting, all are maintained and forward by the said department.

MECHANICAL SECTION

Interpretation:


MECHANICAL ENGINEER

FITTER

HELPER


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There are 3 mechanical engineers, 6 fitters and 9 helpers working in 3 shifts. The

maintenance of all machines in the organization is to be maintained by the said department.

If some mechanical trucked the concerned in charge has to inform the mechanical engineer.

He will make repair it. If not possible by him the specialist will be called from outside.

PROCESS SECTION:

The process starts from accepting raw materials from pulp mill where the raw materials

is stored in the form of Kraft paper.

SORTING: In this step the raw material accepted from pulp mill will sorted i.e., separated into

Kraft paper, stored them differently in different 2 godowns with the capacity of 65 tons each.

PULPING:

The sorted papers were transferred to plumping process where the pulp is formed

of them. The pulp is formed by mixing raw materials. Paper with required quantity of water

is flowed from top and all paper is converted into pulp.

The machine used for the purpose is HYDRO PULPER.

SCREENING:

Thus formed pulp is transferred to machine through pipes where the weighted

substances like metals, pins, and steels, sand, soil from pulp is removed and passed is to the

decter section.



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THICKENER:

Thus purified pulp transferred to decter machines where dehydrating is done i.e., the

water is removed from pulp and that water transfers for the further use in hydro pulper. The

water content removed with the help of 3 f screen, magnet valve and sandraf.

Then the pulp is passed through TDR (Trial Disc Refiner) where pulp is softened and

ph of pulp is tested and the chemicals like Rosin, Alum, and Goargum. There are totally 5

decters for 1 pulp mill.

Thus softened pulp is passed and stored in chest box. There is 1 head box for 1 pulp.

Then from head box the pulp is passed through various following machines and undergone

following process.

HEAD BOX:

There is 1 synthetic wire the slurry pulp is constantly supply to synthetic wire. The basic

purposes of this synthetic wire is to get the basis paper web format.

VACCUME PUMP:

There are 5 vaccume pump used for removed water from pulp, with help of synthetic

wire boxes are below synthetic wire. Wire will carry slurry of pulp. Vacuumed pump

queering water from pulp. Water contain in end of wire part is around 80% drying the

synthetic felt. Then passed to press section.



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PRESS SECTION:

There are two different press machines for 1 pupl to form one single paper web. The

web board contains 1 layer of a pupl. In this section, the moisture content present in the

paper web is also removed.

The moisture content of paper web is maintained and after 2 nd press in the range of 52

3% by applying pneumatic load at both the press roles.

DRIER:

Then from press section the paper web passes to dyers through belts. The dryers are

used to dry the paper web through steam generated trough boilers.

In the initiation is done by drying the web slowly. When the web moves to pre-dryer

where the web is dried again with high steam and when it is passes to MG Cylinder it dries

out the condensed water continuously,. Then the paper web ends and the paper web is fully

dried out and all content of moisture is removed finally.

When the web transfers to MG Cylinder there is 35 to 40% moisture is present and

which comes down to 20% when pass through past Dryer. There are totally 1 MG Cylinder

and 7 pre-dryers and 4 past dry [per machines used.

POP REEL:

If the paper was ordered in reels then the paper is reeled out with the help of this

machine. It is a machine which is having a round roll and which reels the paper.

REWINDER:



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It is a machine which cuts the paper reels into required sizes. The reels are cuter by

circular knives. Breaks and core knives.

FINISHING HOUSE:

After cutting the paper board they were brought to finishing house where segregation

of acceptable and non acceptable paper is done by physical testing.

DUTIES AND RESPONSIBILITIES:

`The defective reels such as creasing; cocking, over dry size variations, damping anddamage reels should be rejected and kept alone.

The accepted reels should checked physically may ream of 1 bundle and packed with

clip, plastic sutali, pp woven, wrapper properly and paste the labels containing

manufacturing date, size and number of sheets, GSM, BF and weight.The weight of each

bundle 200 to 800 kg and packed in Hessian cloth and put proper identification mark and

record.

WORK FLOW MODEL

PROCESS FLOWCHART



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ADMINISTRITIVE MANAGEMENT COLLEGE BANGLOREADMINISTRITIVE MANAGEMENT COLLEGE BANGLORE

STOCK PREEPARATION OF BOTTOM LINEARPULP

STOCK PREPARATION OF TOP LINEAR NO.1 PULP

STOCK PREPARATION OF TOP LINEAR NO.2 PULP

PAPER MACHINE WET END SECTION

DRY END SECTION

FINISHED SECTION

SORTING OF RAW MATERIALS

Moisture test

Freeness test, consistency, & PH

Freeness test, consistency

, & PH

Freeness test, consistency, & PH

Consistency testMoisture test

Consistency testFinal test

28


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The Work Flow Model Of The Company:

SORTING OF RAW MATERIALS:

Responsibility : Q.A. Inspector

Purpose : To segregate the unwanted materials

Instructions:

1. This procedure is restricted for white cutting material only.

2. Remove the packing of each bundle of white cutting and keep a side. The packing

material shall bee considered as color record and used as raw materials for bottom

layer

3. Unwanted materials such as dust, sand , rubber, plastic strips, etc. shall be removed.

4. Unwanted materials shall be collected in a drum and shall be used as a color record.

5. Sorted white cutting materials shall be stacked for further process.

STOCK PREPARATION IF BOTTOM LINEAR PULP:

Purpose : Slushing, Screening, Refining, & Chemicals mixing of the pulp.

Responsibility: Pulp mill operators.

Machineries : Hydropulper-01 No.

Sand trap 01 No.

Johnson vibrating screen 01 No.

Thickner 01 No.

Turbo-separator- 01 No.

Dry disc refiner 01 No.



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Instructions:

1. Feed the back water form E.T.P to hydro pulper upto th level and starts the motors.

2. Feed the acceptor raw materials through the converter.

3. Pump the slushed pulp to sand trap and allow the pulp to flow through the sand trap.

The dense particles , sand, grit and iron particles are settled down. Clean the sand trap

once in 15 days for better result.

4. Clean the hydro pulper once in a shift.

5. Pump the sand trap accept to turbo-seperator. The accepted stock passes to thickner

and rejects will again feed to Johnson vibrating screen.

6. Collect the thickner accepts in chest No.2 and start the empty tri-disc refiner and pass

the pulp through a pump. Apply the load upto 75 5 ampsin order to achieve the

required freeness.

7. Take a refined pulp to chest no.4. Add chemicals as per annexure-1 till obtaining the

Ph. In between 4.0 to 4.5 and pump to chest no. for machine use.

8. Keep the surrounding area always clean.

9. Check the consistency performance of the machine chest pulp once in 4 hours and

maintaining 3.0 0.5%.

STOCK PREPARATION IF TOP LINEAR NO.1 PULP:

Purpose :To refine the pulp and to add chemicals to obtain the Ph properties.

Responsibility : Pulp mill operation.

Machineries : Hydropulper 01 No.

Tri-disc refiner -01 No.

Inclined screen -01 No.



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Instructions:

1. Fill the hydro pulper with fresh water up th level.

2. Start the hydro pulper motor and put the sorted white cutting raw materials slowly

and uniformly.

3. Take the slushed pulp to chest no.1 through pump.

4. Pass the pulp to chest no.2.

5. Start the tri-disc refiner apply the load 75 5 amps. And recalculate the pulp to the

same chest for 2 to 2:30 hours in order to achieve the required freeness value.

6. Add the chemicals as per the annexure-1 till obtaining the Ph 4 to 4.5.

7. Pulp the pump to chest no.3 for machine use.

8. Check the consistency of the machines chest pulp once in 4 hours by consistency

meter and maintain in between 2.5 0.5%.

STOCK PREPARATION IF TOP LINEAR NO.2 PULP:

Purpose :To refine the pulp and to add chemicals to obtain the Ph properties.

Responsibilities :Pulp mill operators

Machineries :Hydro pulper 01-No.

Sand trap 01-No.

3-F screen 01-No.

Inclined screen 01-No.

Tri- disc refiner 01-No.



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Instructions:

1. Start the hydro pulp motor and back water pump and fill up to 50% level and put the

sorted white record material slowly and uniformly.

2. Pump the slushed material to chest No.4 through the sand trap add the bleaching

powder as per annexure-1 and wash the pulp thoroughly by re circulating the pulp

through the inclined screen. Clean the sand trap once in 15 days.

3. Start the 3-F screen and back water pump and pass the pulp to chest No.5 .

Add the chemicals as per annexure-1 till obtaining the Ph in between 4.0 to 4.5.

4 . Start the try disc refiner apply the load 75 5 amps and re circulate the pulp to the

same chest for 2 to 2:30 hours in order to achieve the required freeness value.

5 .Pump the pulp to chest No.3 for machine use .

6.Check the consistency of the machine chest pulp once in 4 hours by consistency meter

and maintain in between 2.5 0. 5% .

PAPER MACHINE WET END SECTION:

Purpose :To make the wet paper web.

Responsibility :Shift incharge and Mould operators.

Instructions:

1. Fill the back water tanks with fresh water (or) E.T.P recycled water.

2. Start the empty machine by starting the D.C variable motor.

3. Start the fan pumps which pumps pulp and water to centric cleaners.

4. See the whirling action at all nozzles.

5. Tate the accepts of centric cleaners pump to individual dilution tanks and add back

water through a separate pump.

6. 6.Adjust the edge cutter as per the required size

7. Keep the mould showers always clean .



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8. See all the layers that are formed at separate mould are become a single wet sheet,

which is carried by an end less bottom pick up felt to press section.

9. Adjust the pneumatic loads at 1 and it press so that the moisture % of the wet web

living 2nd press should bee 58 3%.

PAPER MACHINE DRY END SECTION:

Purpose : To dry the wet paper web and cut as per customer size.

Responsibility :Shift incharge and steam operators.

Machineries :Dryers

M.G

Calendar

Cutter and Rewinder

Instructions:

1. Heat all the dryers and MG by opening the steam to all dryers and MG .

2. Pass the wet web to pre dryer group manually and adjust the steam by controlling thepressure at each dryer with the help of pressure gauges which are indicative so that the

moisture contains of the web leaving pre-dryers should be 40 20%.

3. Pass the sheet to M.G so that the top surface will get glazed along with drying

maintaining the moisture content of the sheet leaving the M.G in between 20 2% by

controlling the steam at M.G .

4. Pass the sheet to past drying group and dry the sheet so that the moisture content of the

final sheet should be 6.0% 1 % .

5. Pass the sheet through calendar to the bottom surface smooth and then feed the sheet at

cutter machine to cut according to customer required size and stock it in finishing house

with identification label.

6. Reel the paper in pope reel and then rewind it in re-winder as per the orders are in reel

form.



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TRANSPORTATION :-

The company doesnt have its own transport vehicles. It hires the vehicles on rental andlease basis. The main transportation is done through road transport and railways.

MACHINES :-

The company brought machines which were installed in the company from the

following companies

Parason TDR, Delhi

J & K Engineers Pvt., Ltd, Chennai.

Machine Industries Pvt. Ltd., Kolkatta

Unique Enterprises, Pune

PACKAGING SECTION :-

The packing of the kraft, Board is done in finishing house. According to demand

of the customer the krat board and pop reels are packed in various sizes with the help of clip,

plastic sutali, pp woven, wrappers and the stitched. All the reeling, cutting of pop reel are

done by automatic machines. The stitching pasting, weighing are done physically.


PACKAGING / FINISHING

INCHARGE

PACKING

SUPERVISOR

FINISHING

CLERK

STICKING

SUPERVISORFINISHER


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MARKETING DEPARTMENT

Importance of Marketing

Marketing is a social process which individual and groups obtain what they

want and what through creating, offering-and freely exchanging products and services

of value with others. The essence of marketing is exchange or a transaction intended

to satisfy human needs and wants through an exchange process. A demand is a want

for which the consumer is prepared to pay a price. A want is anything or a service, the

consumers desires or seeks. Wants becomes demand when backed by purchasing power.

A need is anything the consumer fells to keep himself alive and healthy. A

transaction consists of value between two parties. A transaction differs from a transfer. A

transfer may receive nothing in return. The aim of making is to make sales n order toearn reasonable portable profit for the producers.

Objectives of Marketing

Barker and Anshen say the end of all marketing activities is the satisfaction of

human wants through the satisfaction of human wants, profits are rewarded to the

business and addition benefit is the inducement of marketing. Now the time has

changed and the objective of marketing is more than security profit. The following are

the main objectives of modern marketing activities.



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Marketing Mix

Marketing mix is a term used to describe the combination of the four inputs

which constitute the core of a companys marketing system. They are :-

1. Product

2. Price

3. Place

4. Promotion

MARKETING POLICY:

In the direction of achieving the companys mission, the marketing team- PIP endeavors for

maximization of sales and realization for the company products while meeting the

customers requirement to heir all round satisfaction.

This department is headed by marketing manager and maintains a wide area of

distribution network. The company occupied a large of market in the state as well as in other

state namely Maharashtra, Tamil Nadu, Kerala etc.

The company supplies it product to its main dealers, customers in various following regions.

Anil Paper Board Bangalore.

Nikhil Agencies Bangalore.

Sushen Paper (P) Ltd. Bangalore.

Laxmi Paper mart Bangalore.

Deepa Packers, Mangalore

Mysore Paper Corporation Secundrabad.



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Sai Baba Paper Mart, Hyderabad.

Vishwa Kutumb Pvt Ltd Hyderabad.

Goli Iswariah Hyderabad

Direct Consumer Reliance Packaging Industry Chennai.

Jahan Enterprises, Shivkashi.

Krishna Enterprises, Chennai

Adhunic Packaging.

Paper Combasins Kerala.

Shreerang Agency Mumbai.

Vishwas Trading Company Pune. Candid Paper Mumbai

DISTRIBUTION NETWORK:

Under the distribution method the product is sold to the dealers and consumers

and consumers on consignment selling method. The advantage of consignment selling is that

manufacturer runs no risk in having possession and making sales of the product through the

dealers, retailers to finally consumers. Sometimes consumers directly purchase the product

from the company also.

VARIOUS ADVANTAGES OF THIS CHANNEL :

Helps in production function.

Matching demand and supply gap.

Stabilizing the prices.

Promotional activities.

Consumer will get goods at cheaper price.



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DISTRIBUTION NETWORK OF THE COMPANY

LABORATORY :

There are 3 lab assistants are for each shift the tab assistant has to check the GSM

(Gram Square Meter), size, weight, thickness, Ph stiffness, ash content, consistency, BF of

every paper product, the square of every paper is cutted down tested in laboratory.

If lab assistant checked that the produced paper board is not of the required quality he will

reject them and inform the production manger and other required quality paper board will be

produced.


DEALER WHOLESALER

MANUFACTURER

DISTRIBUTOR

RETAILERDEALER RETAILER

CONSUMERRETAILER CONSUMER

CONSUMER


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The following machines were used in the testing process. :-

BF Tester

Hot air oven

Weight Machine

Physical balance.

Consistency tester.

Essae digit

Freeness tester.

Cob tester.

Ash tester

Ph tester.

.

QUALITY DEPARTMENT

Quality assurance division is a customers representative. This department acts as

communicating channel between customers and production department. They make steel for

automobile industries and also for stimulus tubes. It is also used for transportation of oil and

any other fuel.

In quality assurance department, marketing department plays in important role. The

orders of the customers will be received by the marketing department, then department. This

process is called as Contract Review.

Then the quality assurance department translates the need of the customers to the

production department. This department also inspects the cost And rolled products. It checks



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the materials before it is taken for production and also tastes the products before dispatching

to the customers. Ever since the procurement of the raw material till the dispatch of the final

product the function of observation and examination of the quality control department is

keen and careful.

As there are two divisions in the company the quality department for each department

is different. Quality inspection is carried out for both the incoming raw materials and out

going finished goods.

The raw materials should be as per the standard size, volume and with chemical composition

and metallurgical composition.

QUALITY CONTROL :-

In Karanja Industry,there is a laboratory in the plant to check the quality of paper

manufactured and it check the quality in every lot. It sends a report of quality of paper to

quality manager, if the manager feels quality of paper dues not meet the customer

requirements. Then he sends report of corrective action to be taken production manager,

where in the takes proper corrective actions according to the report to meet the customer

requirements and satisfaction. The rejected paper due to bad quality is reused in process in

hydro pulper machine by making pulp of rejected paper so there no wastage 100% utilization

takes place.

Inspection of Raw materials

Laboratory testing method

AIMS



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To inspect the quality of raw material and finished products and to maintain the

grades as per the customers requirement.

FUNCTION;

1. Adding internal/external chemistry to attain specified standard.

2. Testing the manufactured products subjects to any damage or not.

3. To check the raw materials.

4. Identifying customer

5. Indentifying needs.

6. Converting needs into specialization.

QUALITY POLICY

Karanja Industries Pvt. Ltd is committed to achieve total customer satisfaction

through adoption of state of art manufacturing and processes with continual improvements.

Karanja Industries Pvt. Ltd is also committed to improve the quality of work life of its

employees through improved work practices.

QUALITY OBJECTIVES:

Customer Satisfaction: Maximization of Customer Satisfaction by consistent

supply of Quality Kraft & Duplex Paper.



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Supplier Quality Assurance: Provide technical support and guidance to our

suppliers through Quality Assurance Programmes to ensure highest Quality of

purchased materials. Supplier is a critical link in our Quality System.

Employee Development: Development and motivation of all employees by providing

necessary training and support to bring out their full potential.

PURCHASE SECTION

PURCHASE MANAGER

ASST. MANAGER

CLEARK

The purchase department is headed by the purchase manager, who takes the

responsibility of purchasing the required qualitative and quantitative raw materials. All

purchases are made by the company or all requirements needed by the company will

purchase through him only.

If some department of the company required some any materials they have send

requisition letter informing about the quantity and quality of materials required. The

purchase manager after accepting the letter, he purchase and sends them to concerned



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departments. The purchase manager has to maintain day-to-day purchase records and same

and to be reported to the M.D.

Daily 50 tons of paper has to purchased day-to-day purchased by him to run the

machines of pulp mill.

The following are prices quotes in purchasing of raw materials

White Record

White Cutting Depend upon Market Price

Color Record

STORES SECTION :-

It is a one where all the necessary daily-required materials are stored and are issued

against requisition slip by concerned department chief.

The department is maintaining Bicard MRV. (Material Receipt Voucher ledger books of

every product which coming in and going out of department.

MISSION

MINIMIZE THE COST OF INVENTORY.

VISION

ATOMIZATION OF CURRENT SYSTEM.

Karanja Industries Pvt. Ltd adopts FIFO [First in First out] method to issue the

materials in order to avoid obsolescence of material and company finds this method as most



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convenient to handle the inventory. Store department is a common department both pig iron

and foundry division but it maintains different documents for each division.

Futures Growth and Prospects:

As the company is committed to produce quality products, it results in attracting more

number of customers and to beat the competition.

As per the infrastructure is concerned Karanja Industries Pvt. Ltd has a well equipped and

sophisticated infrastructure which helps the company to meet the customer demand in time.

By looking at the present infrastructure, skilled workforce, technology and emerging demand

condition, company is planning to put one step ahead i.e. by diversifying to steel

manufacturing industry.

As the demand for the automobiles are increasing the demand for the products of Karanja

Industries Pvt. Ltd is also increasing, so Karanja Industries Pvt. Ltd has got a clear and

bright future



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SWOT ANALYSIS

The main Strengths, Weaknesses, Opportunities and Threats of the company which have

been observed and studied in the organization are as follows:

STRENGTHS:-

Good cliental base.

Technical and experienced manpower.

Automated and highly sophisticated machines.

ISO 9002 certified company.

Government support acting as the backbone for the company.

Well planned layout helps for the smooth functioning of work & excellent

infrastructure can create better working environment.

WEAKNESSES:-

Less emphasis on training.

Location of plant resulting in high transportation cost.

Lack of motivation and creeping inefficiency.

Price of goods is comparatively high.

OPPORTUNITIES:-



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Growing Demand for Kraft & Duplex products.

Easy availability of human resource according to the requirement.

Opportunity to tap national market.

Opportunities exist for the company in cutting the cost of production and thereby to

gain untapped market opportunities.

Due to innovation and advancements in technology, there is a scope for recruiting and

retaining the specialized employee for the specific job.

THREATS:-

Changing Government Regulations.

Pollution Board Norms .

New competitors like Gemini Graphics and Veerji Paper Mill are enters in market

will dilute in the market share of the company.

Increased transportation cost due to loading recreation & increasing fuel prices.

Inconsistent power supply.



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FINDINGS AND SUGGESTIONS

FINDINGS:

The organization is one of the major industrial setups in Bidar providing

employment opportunities. It is spread in 85 acres of land including the lands and the

manufacturing unit. More efforts are required in the marketing field and there is no recruitment in the

company from last few years

It offers employment to more than 506 no of employees at various levels and in

different capacities and the mode of employment ranges from permanent contract to

daily wages.

Dealers are showing increased interest in purchasing the companys board because

of high profit margin.

Usage of modern technology.

It is having centralized control system which is not useful for sudden decisions.

Dealers are showing increased interest in purchasing the companys board because

of high profit margin.



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They are having good and excellent infrastructure and ultra-structure facilities.

The employees employer relationship is very good.

.

SUGGESTIONS:-

Means communication should be made through telephone, internet, and websites

and also through fax. Good means of combination system like transport facility should be

made easy to deliver the goods in time.

Keep the workers well contented and reduce labor turn over rate.

Company has to improve its performance by reducing cost so that the company

can able to achieve the profit in future.

The company can introduce innovative quality practices to cut costs in various

process of production and increase competitiveness in the market.

Organization could re-design the structure as per the current environment to allow

freedom and empower the management for decision making.

Skills and motivation level of the employee can enhanced by providing effective

training.

To conclude company should minimize its overall cost and its operation for the

benefit of the company.

Effective, charismatic leadership is required who could steer the company

towards profitability by controlling the leakage of available resources and

overcoming the organizational weakness.



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The company had to capture local market to satisfy the local customers .

Have to replace the new machine in place of the old machine, as replacing thenew machine with the old it costs too high but it can be done as follows:

Taking loan from the bank to implant the new machine.

Installing new machine with the exchange of the old by deducting the depreciation

and paying the remaining amount.

Monitoring every month whether the machineries working fine and lubricating

whenever required.

CONCLUSION

The company has to overcome the following,

The main objective of the in-plant training is to gain knowledge about functions of

an organization, its back ground, Nature of business, its working and analysis of various

product profile of the organization.

Staying in the KARANJA PAPER MILL PVT LTD factory for almost a month

was a platform for me to know its business conditions in the initial stage and gradual growth.

The study helped me to view the process of producing various products produced in

the factory. To know the performance ofKARANJA PAPER MILL PVT LTD. Produces

good quality white cutting duplex paper board and Kraft paper board. Workers are highly

satisfied with wage and salary administration and welfare facilities.

To conclude organizational study at KARANJA PAPER MILL PVT LTD. helped

me to relate the theoretical knowledge to the practical environment and enlightened me with

the knowledge regarding.



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BIBLIOGAPHY

BOOKS:

Title of the Book Marketing Management.

Name of the Author Philip Kotler.

Title of the Book Financial Management.

Name of the Author I. M. Pandey.

Title of the Book Financial management

Name of the Author Prasanna Chandra

Title of the Book Human Resources Management

Name of the Author Dr. Aswathappa

By Observation & Magazines & Reports.

Website: www.karanjaindustriesltd.com

www.google.com

http://www.karanjaindustriesltd.com/http://www.google.com/http://www.karanjaindustriesltd.com/http://www.google.com/


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