Elevating container board Manufacturing in India

In a stride towards elevating the containerboard manufacturing landscape in India, Valmet delivered Sri Andal Paper Mills with advanced board making technologies for their new PM 4 in Tamil Nadu, India.

This collaboration between Sri Andal and Valmet supported the start-up of a modern containerboard production line with improved quality and efficiency.

The future of paper in India lies in the realm of packaging paper. The nation’s strong favorable demographics, growing retail and e-commerce industries, and demand for processed and packaged food represents some of the prime factors, driving the market growth. As the country propels towards achieving a 5 trillion economy. Paper is expected to play a significant role in this economic growth. With brands switching their packaging supplies from non-renewable materials to paper-based packaging materials made from renewable resources. Notably, the packaging segment is experiencing steady expansion, with a Compound Annual Growth Rate (CAGR) of 6.63% for the forecast period of 2022-2027. This growth has caught the attention of global paper manufacturing companies, who are now focusing on India and have already announced upcoming projects in the country.

This collaboration between Sri Andal and Valmet supported the start-up of a modern containerboard production line with improved quality and efficiency.

Looking ahead, the paper industry in India will face intense competition in all segments, emphasizing the importance of quality, cost, and timely delivery. To stay ahead, paper manufacturers must leverage technology to gain competitive advantages and meet market demands effectively. Technological advancements will enable the industry to innovate, improve efficiency, and optimize production processes, thereby enabling it to stay competitive and fulfill the evolving requirements of the market.

“As I said, brands are now looking forward to paper-based packaging materials made from renewable resources. This transition aligns with the global sustainability movement and enhances the market prospects for paper-based packaging. This shift is propelling the demand for container board and corrugated boxes in Indian market.

The corrugated box manufacturers are competing to deliver the boxes in line with the global value of the brand they are supplying. This will give them global acceptance. In order to meet their expectations, mills should provide superior quality container board.

Mr. Rajithlal Janaki, Business Unit Head of Sri Andal

“Now the trends are towards box lightweighting and the customers are looking for lightweighted boxes without compromising strength”, says Mr. Rajithlal Janaki, Business Unit Head of Sri Andal”

Key technologies from Valmet

“The specific capabilities we are looking for when selecting a supplier are technical expertise, customization and flexibility, quality and reliability, innovation and technological advancement, after-sales support and service, energy efficiency and sustainability, cost-effectiveness, reputation, and global presence. Valmet met our requirements and expectations and we decided to go with Valmet for key technologies for the new PM 4 project.”, summarizes Mr. G Chellamuthu, General Manager of projects at Sri Andal.

PM 4 produces a range of recycled liner, recycled fluting, and corrugated kraft grades, covering a basis weight span of 70-300 g/m2. Valmet’s comprehensive delivery included three OptiFlo Fourdrinier headboxes to ensure precise profiles and optimal formation. Additionally, the package included an OptiPress Linear press section, which not only enhances the final product’s quality but also offers high dewatering capacity and smooth operational performance.

Mr. G Chellamuthu, General Manager of projects, Sri Andal.

“We compared leading technology suppliers in India based on parameters like technical expertise and flexibility, and Valmet exceeded our requirements and expectations. ”, summarizes Mr. G Chellamuthu, General Manager of projects, Sri Andal.

The installation also featured an OptiSizer Film size press equipped with a supply system. To support the project’s initiation, a startup package of spare parts and consumables was provided, alongside the Valmet DNA machine control system, Valmet IQ quality measurement system, and connectivity to the Valmet Performance Center together with remote On-Demand Expert Support.

“With the key technologies from Valmet, we can simply accomplish the strength properties of the containerboard we manufacture. Valmet OptiFlo Fourdrinier headboxes enable our team to retain proper formation, and fiber orientation. They are superior and fulfill our requirements through their wide flexibility and quick response. Valmet OptiPress Linear gives us good dryness. This makes the process energy efficient and sustainable consuming less steam at the dryer section. The design and technology of Valmet OptiSizer Film ensures even application of surface size starch across the paper width, resulting in uniform end product quality”, summarizes Mr. Rajithlal Janaki.

Paper machine clothing agreement for simplified daily operations and optimized start-up performance

Sri Andal and Valmet also signed an agreement for the supply of paper machine clothing including formic fabrics, press felts, Valmet Black Belt shoe press belt and dryer fabrics. “Clothing performance is good in terms of sheet consolidation and stability. We achieved good drainage control and formation with the fabrics. Valmet’s technical support is very good and various types of analysis were done with the latest measuring equipment to evaluate the performance of all the fabrics,” says Mr. G Chellamuthu.

Smooth start-up according to plan

The PM 4 started up in December 2022. “There are always challenges and unexpected issues in all major investment projects. In this project Valmet was extremely responsive, adaptable, and helpful in completing the project on time. We stayed on schedule and commissioned and produced sellable material within the allotted time frame.”, says Mr. G Chellamuthu.

“Valmet is extremely cooperative partner, providing timely assistance at all stages of the project and commissioning. ”

Online assistance is amazing, and there is usually a solution available in a short period of time. “Valmet is just a phone call away,” my team used to say”, concludes Mr. Rajithlal Janaki.

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