A journey to enhance operational excellence

Established in 1962, JK Paper is now a major player in the Indian paper industry, operating three large paper manufacturing mills across the country. With a combined annual capacity of 761,000 tonnes per annum, they are a leader in the branded copier paper segment and a significant producer of coated paper and high-end packaging boards. Since 2019, they have been modernizing their Songadh facility in western India to meet growing market demand.

A holistic transformation

JK Paper prioritized a partner capable of offering high-quality technical support and a wide scope of technology. Mukul Verma, Executive Vice President, JK Paper, explains, “Valmet has expertise across all key areas, from the pulp process to recovery and board machines. They have deep understanding and strong technical expertise in both equipment and automation.”

Valmet IQ Quality Control System (QCS) and the web monitoring system ensure quality at JK Paper.

The comprehensive delivery included a complete fiberline, along with a lime kiln system, a coated board machine with multiple coating stations, and a state-of-the-art Valmet DNA automation package, as well as a Service Agreement to ensure smooth operations and ongoing support.

Breaking fiberline production records

The fiberline and lime kiln installation project involved the delivery of one new TwinRoll press and the relocation of some equipment from another JK Paper mill. This included two TwinRoll presses, washers, screens, MC pumps, and scrapers, which were reconditioned and successfully integrated into the new fiberline with Valmet’s assistance.

We can now reduce our water use by as much as 800 tonnes of water a day.

“We broke a record with our new fiberline. Within a month, it produced 428 tonnes of continuous basis weight per day. This is thanks to Valmet and our team, who got the plant up and running in such a short time,” says C. Muthaiyan, General Manager of Instrumentation and Automation, JK Paper, Songadh.

Mukul Verma, Executive Vice President of JK Paper.

“The burner installed after the kiln allows us to use furnace oil, pet coke, and methanol. Our production costs decreased after we installed it,” says Kartik Patel, Senior Manager, Soda Recovery Process, JK Paper, Songadh. “We’ve also implemented several initiatives to reduce water consumption in the fiberline. We can now reduce our water use by as much as 800 tonnes of water a day,” Muthaiyan adds.

Cutting-edge coated board production

The new BM 5 coated board line produces folding boxboards and solid bleached board, and the scope of supply included a complete 4.25-meter-wide board machine, from headbox to reel, with all the related services.

Valmet TwinRoll presses successfully integrated into the fiberline.

The BM 5 delivery included an OptiPress Linear press section equipped with two shoe presses and a smoothing press. These enhance both the drying efficiency and smoothness of the board. “It’s unique to have two shoe presses in India, along with an additional smoothing press. With the two shoe presses, we’re getting the moisture levels we want,” explains Muthaiyan.

For the press section, JK Paper selected Valmet’s press felts and Valmet Black Belt H shoe press belts. According to Muthaiyan, the felt changes have been smooth, and the press belts have an ideal lifetime.

BM 5 produces folding boxboard and solid bleached board.

BM 5 is the first board machine in India to feature curtain coating technology, with an OptiCoat Layer curtain coating station and three OptiCoat Roll blade coating heads. “We’re very satisfied with the coating technology,” says Muthaiyan. “Curtain coaters are rare in India,” explains Piyush Kumar Mittal. “They’ll definitely give us a competitive edge in the coming years.”

Elevating production efficiency with advanced automation

The equipment delivery is supported by Valmet’s DNA distributed control system (DCS) and a comprehensive package of automation solutions, providing a unified platform for optimized control.

“Valmet’s DCS allows us to monitor and troubleshoot the entire system from anywhere. I can view the pulp mill, lime kiln, boiler, system alarms, and more from my display,” Muthaiyan says. He also finds the playback system outstanding. “Compared with other systems, it provides a clearer view of what’s happened during any issue. This helps us effectively analyze problems and quickly identify root causes, making troubleshooting significantly easier and more efficient,” he says. Integrating the Valmet IQ Quality Control System (QCS) and Web Monitoring System (WMS) has been key to maintaining high-quality standards at JK Paper. “Quality control is essential in paper production. Valmet’s QCS helps optimize moisture levels, reducing breaks and defects,” he notes.

The retrofitted lime kiln has a capacity of 220 tonnes of burned lime per day and is equipped with a burner to burn furnace oil, pet coke, and methanol.

Continuous remote support

Valmet’s Service Agreement with JK Paper ensures ongoing support. “Whenever we face any complex issue, we connect remotely with Valmet’s specialists in India or Finland, and they diagnose the issue and provide solutions. This 24/7 support is very valuable for maintaining our operations,” says Muthaiyan.

The 24/7 support is very valuable for maintaining our operations.

“In addition, the cooperation with Valmet greatly helped streamline and optimize the board’s quality parameters. Quality is critical for coated board. With the help of Valmet’s experts, we were able to achieve the desired quality much faster,” says Bapu Koli, Senior General Manager of Engineering, JK Paper, Songadh.

Collaboration between JK Paper and Valmet has been smooth during the modernization of the Songadh facility.

Continuing a legacy of excellence

The continuous partnership between JK Paper and Valmet underscores how a single supplier providing end-to-end solutions can drive efficiency, reduce costs, and improve overall performance.

JK Paper has now placed an order for a new bleached chemi-thermomechanical pulp (BCTMP) line and a related evaporator line for the same mill, with start-up scheduled for the end of 2025. “Valmet’s unique BCTMP technology will allow us to achieve superior pulp quality and energy efficiency, ensuring that we remain competitive in the global marketplace,” says A. S. Mehta, President & Director, JK Paper Limited.

Text Akhil VP, Weeraya Netwong, Hyun Hee Kang, Veera Silakoski, Kerstin Eriksson, Sofia Forslund, Lisa Kettman-Kervinen

PHOTOS Kartikaya Nagar