In an exclusive interview with Paper Mart, ITC PSPD shared that its current specific freshwater consumption has come down and complies well within the limits prescribed by the Central Pollution Control Board (CPCB) for the pulp and paper sector, that is, 50 m³/tonne for integrated pulp and paper mills and specialty paper mills, and 10 m³/tonne for recycled paper mills. Further reductions in water consumption would require the adoption of advanced treatment technologies, along with economically viable investment solutions for commercially feasible water‑reuse and recycling measures.
Paper Mart: After implementing water reuse, recycling, and closed-loop systems across your mill, what is your current specific freshwater consumption (m³/tonne), and has this figure stabilized in recent years?
ITC PSPD: Over the years, our mills have significantly reduced freshwater consumption by systematically implementing water reuse, recycling, and closed-loop processes across operations. As a result, the current specific freshwater consumption has come down to levels that comply well within the limits prescribed by the Central Pollution Control Board (CPCB) for the pulp and paper sector.
CPCB norms allow up to 50 m³/tonne of product for integrated pulp and paper mills and specialty paper mills, and 10 m³/tonne of product for recycled paper mills. Our present water consumption levels fall within these benchmarks. Any further reduction in water consumption would require significant process or technology‑related investments, rather than incremental operational improvements.
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PM: Under your present operating regime, where water reuse and recycling systems are already in place, what operational challenges have emerged in terms of process stability, machine performance, or water quality?
ITC: High levels of water reuse and recycling can lead to the accumulation of dissolved and suspended solids in water circuits, potentially affecting product quality, process efficiency, and equipment performance. Increased concentrations may also raise the risk of scaling, corrosion, and fouling in pipelines and heat‑exchange equipment, resulting in higher maintenance needs.
These challenges are managed through appropriate water treatment, periodic cleaning programs, automated cleaning systems, and regular monitoring, enabling stable operations and consistent product quality while maintaining high water reuse levels.
PM: At your current level of system closure and reuse, what process, raw material, or product quality requirements limit further reduction in freshwater consumption?
ITC: Product quality requirements and process compatibility place practical limits on further reductions in freshwater consumption. Certain critical operations, such as chemical preparation, high‑pressure paper machine showers, and pulp dilution, require water with consistently low conductivity and minimal contaminants to maintain stable operation and product quality. At the same time, lower overall water usage leads to higher pollutant concentrations in effluent streams, which increases the complexity of wastewater treatment and may necessitate additional treatment infrastructure and investment. Together, these factors define the current operational boundaries for freshwater reduction while meeting quality and compliance requirements.
High levels of water reuse and recycling can lead to the accumulation of dissolved and suspended solids in water circuits…..These challenges are managed through appropriate water treatment, periodic cleaning programs, automated cleaning systems, and regular monitoring, enabling stable operations and consistent product quality while maintaining high water reuse levels.
PM: In highly recycled operating conditions such as yours, do you periodically purge water from the system? What operational factors make this necessary, and how does it define your minimum freshwater intake?
ITC: In systems with high water reuse, some controlled discharge of water is necessary to prevent the build‑up of impurities. As water is reused repeatedly, substances such as salts, solids, chemicals, and organic matter gradually increase. If not managed, this can disturb process conditions, affect product quality, and cause issues like scaling, corrosion, or equipment malfunction.
Periodic purging helps control these risks and maintain stable operations. Freshwater is then required to replace the purged water and restore acceptable water quality. This controlled purging is therefore an essential part of operating reliably while maintaining high levels of water recycling.
PM: With closed-loop and reuse systems already implemented, how do you determine where freshwater must still be used versus where recycled water can be used within different sections of the mill?
ITC: Freshwater and recycled water are used across mill operations based on process needs, water quality requirements, and equipment reliability. Each area is assessed for its ability to handle parameters such as solids, dissolved salts, and residual chemicals. Freshwater is used for quality‑sensitive applications where consistent water quality is essential, while treated or recycled water is used in less critical applications that can tolerate higher impurity levels.
PM: Under these highly recycled conditions, what water quality or system parameters do you monitor most closely, and how do they influence decisions related to reuse levels, purging, or freshwater intake?
ITC: Continuous and comprehensive monitoring of water quality parameters is central to our water management strategy. Key parameters tracked include conductivity, total dissolved solids (TDS), chemical oxygen demand (COD), biological oxygen demand (BOD), pH, temperature, total suspended solids (TSS). Monitoring and analysis of these key parameters ensures current levels of water reuse without compromising process stability, machine efficiency, or product quality.
PM: After implementing available water reuse and recycling measures, have you reached a practical limit to further water reduction under your current operating configuration? What technical or operational factors define this limit?
ITC: With the currently available and commercially viable technologies, and by following industry best practices, the mills have reached near‑optimal water‑use efficiency under present operating conditions.
Although advanced treatment technologies such as membrane filtration and reverse osmosis can improve recycled water quality, their capital and operating costs are several times higher than conventional systems i.e. 30 times due to increased energy use, chemical consumption, and operational complexity. Therefore, these options are not economically viable from either a business or sustainability perspective at present.
Further reductions in freshwater use are limited by the ability of existing processes to handle higher impurity levels, strict water quality requirements to maintain product standards, equipment reliability under more concentrated conditions, compliance with discharge norms, and the cost‑effectiveness of additional treatment systems. Within these constraints, the mills continue to operate efficiently while maintaining responsible water stewardship and consistent product quality.
Also Read: Naini Papers Benchmarks 26-29 m3/Tonne Water Consumption For An Integrated Agro- Based Mill
PM: Beyond your existing systems and processes, what types of improvements or changes would be necessary to reduce water consumption further?
ITC: Further reductions in water consumption would require the adoption of advanced treatment technologies along with investment solutions that are economically viable. The existing systems have already incorporated all proven and commercially feasible water‑reuse and recycling measures. Any additional improvement beyond the current level would depend on new technologies becoming cost‑effective and scalable for sustained operations.
Continuous and comprehensive monitoring of water quality parameters is central to our water management strategy.
