Satellite PCC Plant

Improvement in paper properties like brightness, oil absorbency, porosity, scattering-coefficient are realized by using paper grade Precipitate Calcium Carbonate (PCC). It is valued for its high brightness and light scattering characteristics in paper filling and coating applications. By using PCC, the end user can reduce the consumption of OBA, Titanium, as brightness of the product is very high (min. 95% ISO).

Traditionally, PCC powder is processed into slurry for application in paper. Procurement of dry PCC is expensive due to additional costs involved in drying, packing, transportation and also the availability of PCC is limited. Satellite plant arrangement not only contributes in improving the paper quality, but also brings efficiency in cost, production and supply chain management. The on site satellite PCC plant thus provides the following tangible benefits:

• Providing a ready to use cheaper filler
• Increasing filler loading
• Elimination of freight costs
• In-time delivery
• Reduction in cost of production
• Improvement in Paper properties on par with International quality grades.

In an On-site Plant, PCC is produced in a satellite facility; onsite or close to a paper mill and the resultant slurry is pumped directly to the mill. In this arrangement, all plant and equipment required for producing PCC are installed under lease agreement in the premises of its end user. The utilities like Power, Water, Steam and the CO2 from the boiler stake (going into the air after ESP) are used to make PCC in slurry form for its use in paper application.

Paper companies are faced with enormous pressures to reduce their environmental discharge. Satellite PCC plant has unique environment friendly technology, which not only reduces the energy consumption and drying time, but also utilizes the CO2 emitted from the boilers. At the time of manufacturing PPC, waste CO2 is reacted with lime thus CO2, which reduces its discharge into the air.

The concept of On-site PCC was introduced for the first time in India by Gulshan Polyols Ltd on the site of MAGNUM Papers Ltd, Sahibabad.

Dr. Vasant Chapnekar an eminent technologist, responsible for introducing PCC in alkaline paper in U.S.A. is presently associated with Gulshan Polyols Limited. With joint efforts, the company has installed its technology in manufacturing PCC and supplying it to the customers.

In 2009, GPL undertook a pioneering step to herald a new chapter in Indian Paper Industry by setting up the first Onsite PCC plant with a capacity of 10,000 TPA. This has been recorded in Limca Book of Records.

GPL provides PCC to paper industry in powder form from its merchant plant and in slurry form through satellite plant. After long term association with paper industry & strong R&D, GPL became the first Indian company to develop suitable grades of PCC that can be used in producing alkaline size white paper like writing-printing, cigarette and photocopier paper.

In Europe, already more than 85% Paper Mills are using PCC thru On Site technology. In India, the trend is expected to pick up in the coming years and GPL will have an advantage as a sole player having expertise in running the onsite PCC plant.

The Cost of 1 ton PCC being produced through On Site technology as compared to the existing cost of filler, Talc, is low considering the advantages of quality enhancement in regards to higher brightness, higher bulk and higher opacity.