Established in 1984, Satia Industries Limited is recognized for its modernization, efficiency, and sustainability. The company integrates its manufacturing facility, a chemical recovery plant, and a self-sufficient power generation unit, ensuring cost-effective and environmentally compliant operations. Satia’s 540-acre eucalyptus plantation, developed using Karnal Technology, absorbs treated water discharge and secures future wood raw material needs, demonstrating its approach to sustainability. Through continuous upgrades and eco-friendly practices, Satia Industries has positioned itself as a key player in the industry.
The agro-based economy and sustainable business models are becoming an active part of the business, inspiring more and more companies to achieve self-sufficiency in raw material procurement, smartly recycle and reuse waste and by-products for energy generation, implement effective water management systems, optimize resource utilization, and drive profitability. A notable example of a pulp and paper mill embracing this approach is Satia Industries Limited (SIL), which has successfully adopted an agro-based economy to align with these sustainable practices.
Responsible Pulping
Satia Industries has strategically developed a high level of flexibility and substantial capacity in its pulp production processes by utilizing a diverse range of raw materials.
The facility is uniquely equipped to handle: agricultural residues- including wheat straw and sarkanda, which are vital for producing eco- friendly pulp; wood chips and veneer waste sourced from the wood industry-these materials contribute to their wood-based pulp production; waste paper and pulp substitutes- recycled materials that reduce the need for virgin resources and support sustainable practices.
The plant, located in Sri Muktsar Sahib is renowned as the wheat belt of Punjab. This area is rich in the resources essential for the operations, particularly wheat straw, wood chips, and veneer waste. This geographic advantage allows them to procure raw materials at competitive rates, contributing to the overall cost efficiency.
This approach not only maximizes resource utilization but also minimizes waste and environmental impact. It promotes sustainable agriculture and provides an additional revenue stream for the farming community.
Their use of wood chips and veneer waste, which are byproducts of the wood industry, ensures that the valuable forest resources are used efficiently and responsibly. By repurposing these materials, the company contributes to the conservation of forests and the reduction of deforestation.
The company’s total in-house pulp processing capacity is 480 TPD; out of which 200-300 TPD is agro based, 200-300 TPD is wood pulp processing and 100-150 TPD is waste paper processing.
Eco-Friendly Manufacturing
Over the years, Satia Industries has earned a reputation for excellence and reliability in the paper industry. The company practices environment-friendly manufacturing processes while ensuring compliance with applicable regulations and laws, recognizing the impact of the products on environmental and social aspects.
Central to their eco-friendly manufacturing process is the use of ECF (Elemental Chlorine Free) bleaching technology. ECF bleaching minimizes the formation of dioxins and other toxic substances that can result from conventional chlorine bleaching. This leads to cleaner effluents and less pollution, aligning with our commitment to environmental stewardship.
The use of ECF technology not only benefits the environment but also enhances the quality of our paper. It produces paper that is brighter and stronger, meeting the high standards expected by our customers while maintaining costs and environmental integrity.
The facility, having a production capacity of 2,19,000 TPA, also has made a capex expenditure on a multifuel boiler which is used for fuel generation. All the boilers are equipped with four field electrostatic precipitators (ESPs) to control the emissions. Various consents and authorizations are granted by SPCB under different acts.
- Regulate GHG emissions: In a significant move to mitigate greenhouse gas (GHG) emissions, SIL has implemented a Precipitated Calcium Carbonate (PCC) plant which captures 24,400 cubic meters per hour CO2 produced as a byproduct of fuel combustion in their boilers, thus preventing it from being released into the atmosphere.
- Chemical Recovery Facility: The company has two soda recovery boilers (one standby) within the existing facility to treat black liquor and recover 90-95% of the caustic soda used in the cooking process of pulp.Further, the high-pressure steam that is generated in the process is used to produce power. While this enables the company to turn waste into wealth, it simultaneously achieves the prescribed standards of effluent discharge.
Watch: In Pursuit of Lesser Water Footprint
Effluent Discharge Facility
SIL has adequate capacity for an activated sludge process-based effluent treatment plant equipped with the latest equipment and technology to treat the effluent generated. SIL is conscious of its responsibilities and commitment to the sustainability of the environment, society and law of the land.
The treated effluent meets all the prescribed standards laid down by the State Pollution Control Board (SPCB) and is finally discharged onto the land of the eucalyptus plantation. Also, eucalyptus plants transpire the maximum amount of water through their leaves into the atmosphere.
The eucalyptus plantation of the company, spanning 550 acres and based on Karnal Technology, is used to handle all the treated effluent. As per Karnal Technology, 120m3 of treated effluent is consumed by 600 eucalyptus plants in one acre, in one day.
This technique of eucalyptus plantation has proved to be efficient for the disposal of treated effluent. The eucalyptus plants also supplement the company’s future raw material requirements.
Power Generation
To secure a reliable and quality source of power supply without tripping, the company has invested and achieved self-sufficiency in power over a period of time by establishing a 44.00 MW congregation power plant based on biomass as its fuel.
Rice husk which is being used as fuel is abundantly available at a competitive price in the area. As this is considered green energy; the company earns Renewable Energy Certificates (REC).
Besides, the biogas produced during the anaerobic treatment of wet wash effluent in the bio methanation plant is utilized as fuel in the power boilers. This process partially replaces biomass-based fuels, contributing to a more sustainable and efficient energy use.
Waste Management
All the solid waste generated by the company is disposed of in an environmentally-friendly manner as prescribed by SPCB without causing any nuisance in the adjoining areas. No plastic waste is generated by the company.
Research and Development: A Crucial Component for Sustainability
Environmental and social impact assessments are crucial components of new product development and process changes. The company’s R & D investments include costs dedicated to mitigating environmental and social hazards, making these costs integral to the projects.
Sustainable Vendors
The company aspires to associate with raw material vendors, who comply with environmental and labour laws. In addition, they encourage their vendors to be mindful of responsible business conduct principles such as prevention of environmental pollution, no child labour/forced labour, implementation of safety.
Most of the raw material vendors are located in proximity to the manufacturing units which helps to minimize transportation and related GHG emissions. The company procures its major raw material requirement from within a radius of 150 kms of the plant.
Community Activities to Preserve the Environment
Further to raise awareness and promote sustainable activities such as addressing water scarcity and promoting efficient use of water resources, SIL implements rainwater harvesting systems to capture and utilize rainwater, reducing dependence on traditional water sources.
Apart from that, the company has constructed recharge pits to replenish groundwater levels and ensure a sustainable water supply. They have also conducted awareness programs to educate the community about the importance of water conservation and efficient usage practices.
The company is also committed to environmental sustainability through their afforestation efforts: The company organized tree plantation drives along village roadsides to enhance green cover, improve air quality, and provide shade.
Also Read: Global Scenario: Paper Industry Fueling Corporate Sustainability Initiatives
SDG Targets for Sustainable Future
Under its SDG goals, SIL plans to develop and adopt eco-friendly technologies and practice and collaborate with research institutions for sustainable innovation. Targeting sustainable forest management and to combat desertification and reverse land degradation, the company aims to source paper from certified sustainable forests and support reforestation and afforestation initiatives.
Additionally, to achieve sustainable management and efficient use of natural resources by 2030, the company will implement a waste management and recycling program, optimizing resources and reducing waste.
Conclusion
All in all, SIL has consistently demonstrated a proactive approach to minimizing environmental impact while meeting the growing demand for paper products. Through the adoption of sustainable practices and investing in energy-efficient technologies and effluent treatment plants, the company aims to minimize its carbon footprint and reduce water consumption. By generating power through eco-friendly means and implementing strict waste management protocols, the company exemplifies responsible industrial practices.
SIL showcases how the paper industry can harmonize economic growth with environmental stewardship. By focusing on sustainable sourcing, technological advancements, and energy-efficient processes, the company has demonstrated that profitability and sustainability are not mutually exclusive, paving the way for a greener future while meeting the evolving needs of the pulp and paper industry.
