HANDMADE PAPER PROJECT REPORT

The hand paper industry is one of the important industries under the village industries sector. The industry has over 3260 units producing over Rs.534.56 crore worth of paper and paper products, providing direct employment to more than 37,000 persons in the rural areas out of which 50% are women and also indirect employment to another 10000 people.
Service requirements
1.   Water                   1000 lit./ day
2.   Power                   80 H.P.
3.   Building                2,000 sq. ft.
4.   Drying shed          3000 sq. ft.
5.   Employment          20 persons/ shift

Methodology and process of manufacturing Hand Made Paper

 Cellulosic materials like waste cotton, waste banana stem, mat grass, Palmarosa grass and other agriculture residues are to be collected. These materials have to be collected from different villages. Mixed fibresraw materials are sorted out to remove any non fibrous and metallic portion.

 Cutting
 Sorted fibrous raw material is cut into small pieces (1-3 cm). A handmade chaff cutter can be used for this purpose.

Dusting/ washing
 The cut pieces are dusted and washed to remove dust and dirt particles. The dusting can be done by mechanical duster or by beating the material by hand.

Digestion
 The fibrous raw materials are cooked with caustic soda for 2-3 hours in mild steel vessel (Digester). The pulp is then washed thoroughly with water to get rid of traces of alkali and dissolved matter

 Pulping
 The strips are then put into a treatment vessel and processed with microbes. The bio treated strips are then fed into a beater along with water and sized additives to form a pulp type mixture. This unbleached pulp may need to be treated with non-polluting bleaching agents. The chemicals (rosin and alum) and colour may be added to improve the pulp quality as per requirement.

 VAT processing
 The pulp mixture is spread on a net, which enables the water present to settle down and form a paper sheet. These paper sheets are blotted on a woolen/ gada cloth. Similarly other paper sheets are also mounted and eventually all the sheets are collected in a heap.

 Cylinder Mould Processing
 Cards and boards are processed through cylinder mould machine for pulp formation on to the wire-mesh and then in cylinder mould drum.

 Sun light drying
 Water is drawn out from these sheets with the help of a hydraulic press and then these sheets are detached for the cloth and left to dry in sun light.

Calendering
 After drying these sheets are passed through two heavy rollers or and calendering in between two metal sheets for polishing the papers or boards.

 Cutting
 Lastly the sheet is cut to the required size and shape as required for marketing. The paper thus made can be further converted into bags, box, files and pads etc. depending on the order to be received to the unit. Three production units can supply 25% of paper and cards to the conversion unit. Depending on the market order the unit can operate on converting paper into various products.

 Equipments
 The equipments and machines required includes (i) Rag Choppers (ii) Beaters (iii) Pulp tanks (iv) calendar machines (v) Agitators (vi) Hydraulic Press (vii) Cylinder mould, vat power driven machine etc.

 Economics
 For producing, 40 tonnes of hand made paper annually the capital investment required is about Rs. 4 lakhs and the working capital Rs. 1.25 lakhs. The unit is expected to earn a profit of Rs. 1 lakhs per year and employ 20 persons.

Collection of cellulosic material
 Sorting out for quality control
 Beater pulping   processing with water (30 minutes)
 Sizing with natural additives (rosin, Alum, China clay, Talcum power)
 Cylinder mould processing          Vat processing
(VAT/ AUTOVAT method)
 Paper boards/ sheets                              Blotting on Cloth
 Sun light drying  Screw pressing
 Paper cutting                                         Calendering/ polishing
 Packaging                                              Market supply

 Production conservation Market supply

 Advantages Process in Paper Making
 In conventional paper making process, cellulose is obtained from trees (deforestation) after chemical and mechanical treatment with the result that only 30-40% of the stating material is useful for paper making, whereas in MCRC paper process 85-90% of cellulose is obtained from tree usufructs, followed by microbial/ mechanical pulping by using non polluting additives and dyes from natural sources.

Project Viability/ Cost Benefit Analysis
            Production capacity                    100 kg/ day (3 ton/ month)
            Employment (regular)                 20 women/ shift
            E.B. Power                                 80 HP
            Water                                        1000 L/day
            Project cost                               Rs. 100,000

 Building 3000 sq. ft. drying shed & 2000 sq. ft. working space with thatched roof are required.

Expenditure
Raw material
(a)  (Banana stem, cotton, agri residues                           Rs.  1300.00
     130 kg / day @ Rs. 10/ kg.)
(b)  Additives (True wax, Talcum powder,                         Rs.    220.00
Starch & Alum:(for 110 kg. raw material @ Rs. 2 kg.
(c)  Labour; skilled (trained) 4 persons @ Rs. 100)              Rs.    400.00
(d)  Power charges (80 HP, 40 units @ Rs. 5)
(e)  Transport, maintenance, overheads & administration   Rs.    100.00
Total production cost / 100 kg. paper                         Rs. 2,200.00
      100 kg. paper.
            Expected sale (Rs. 40/kg.) of 100 kg.                   Rs. 4,000.00
            Net income / day                                                Rs.1,780.00

Uses:

 Under pressure of growing demand and for product diversificiation, handmade paper
manufacturing units are using materials like mesta, hemp, bagasse, etc for making
this grammage papers. Handmade paper indutry kmanufactures paper such as
drawing paper for artists, permanent document paper, dark coloured card sheets,
deckle adged stationery, exclusive greetings, varieties of fancy decorative wraps,
unique carry bags, water mark paper certificates, filter papers and pads. Insulation
paper besides other cultural grades like covers, duplicating paper and tissue paper.
These prodcuts have good demand in the domestic market and find usage in the
stationery, greeting card, packaging industry and have tremendous unexplored
potential in export markets.

HANDMADE PAPER- ENVIRONMENT SUSTAINABLE INDUSTRY

Handmade paper Sustainable Environment Industry

 To reduce the amount of paper waste generated by offices
 To reduce the demand for paper made from virgin wood fibre
 To save our Planet Earth from Global Warming and Greenhouse Effect
To stop deforestation and to save our forest reserves.

It is well known fact that, to produce 1 tonne of paper from virgin pulp require 17 large trees, which leads to more tree cut and more deforestation. When forests are cleared, natural habitats are destroyed or disrupted, species may become extinct and native communities dwelling in the forest areas are impacted. Besides, cutting down old forests leads to a loss of diversity. Trees also serve a function of soaking up carbon dioxide, which is one of the main greenhouse gases that accelerates global warming
The Warning for the Environment
The average office worker throws away 35-50 kg of paper per year. In Singapore, 500,000 tonnes of paper is thrown away every year, and this is equivalent to the destruction of about 8.5 million trees.

The Care for the Environment
There is a growing concern around the globe for preserving our forest reserves. The "Greenhouse Effect" has led people to become more alert about the environmental concerns. It has been seen that, in the recent few years various corporations, communities, government agencies and others are coming forward to promote products and technologies that lead to the preservation of the environment.

Global Benefits of Handmade Papers
The paper-making process uses energy, water and chemicals and produces wastes. Paper made from recycled fibres or Handmade Paper requires at least 50% less energy and up to 75% less water than making it from virgin fibre. It also produces up to 90% less wastewater and reduces air pollution by 70%
Common Benefits of Handmade Paper
Today, there is a revival in homemade papermaking crafts. It's a good way to recycle waste into wonderful possibilities. Handmade paper is environment friendly as cotton rags and other waste products are converted into something meaningful by recycling. This leads to less deforestation.

Benefits :
Use of non-wood raw materials, thus saving trees.
Made with pollution free methods as solar energy is used extensively.
Acid free.
Higher tensile, bursting, tearing and double-fold strength as compared to mill made paper.
Fine and elegant quality.

INTERNATIONAL HANDMADE PAPER MARKET

International  Handmade Paper Market

The Indian handmade paper industry has made a big dent in the international market because the Indian handmade paper and value added products have made a quantum jump. According to an estimate, value added products have the share of more than 70% of total exports.
 For the last two decades the handmade paper industry has been exporting certain exclusive varieties like deckle edge stationery drawing paper, marble paper, mottle paper made from jute, wool, algae, straw, grass etc and recorded significant growth in the export sector.
Countries like Indonesia, Malaysia and Philippines have already emerged as `handmade paper giants'; India is being looked upon as the country with the maximum growth potential. The country is almost self-sufficient in manufacture of most varieties of handmade papers. There has been phenomenal growth in the export market for Indian Handmade Paper and its products, especially in the developed countries like the United States of America, Webecome hundred percent export oriented units and helped in increasing the foreign exchange of the country
Foreign buyers like US, Germany, UK, Canada, Italy, Sweden, Australia, Singapore and Hong Kong are purchasing handmade paper from India because handmade paper production in India by all means is as low priced as compared to the other handmade paper producing nations.
 The demand of handmade paper at international level is on the spurge due to increasing environmental awareness.
Countries like Philippines, Japan, Korea etc are producing handmade paper in different varieties on the basis of colors, shades, thickness, smoothness, size etc. To the limited extent the people are recognizing this paper for eco-friendliness.

INDIAN MARKET OF HANDMADE PAPER

Handmade paper market

The Indian handmade paper industry has been identified as one of the village industry and the industry has seen significant growth in last one decade because of improved demand not only on national level but at the international arena. As per estimates, there are nearly more than 450 handmade paper units scattered all over India producing nearly 50,000 tonnes of handmade paper & board. The Indian handmade paper industry had grown remarkably in the recent past wherein the production of handmade paper industry has reached to a turnover of Rs 250 crores.
Due to increased literacy, industrialization and modernization, the per capita consumption of the paper and paper board has increased remarkably from 4.5 kg in the year 2000 to nearly 6.5 kg in the recent past. This industry provides employment to about 10,000 people and most of them are situated in the rural areas.
Although, the per capita consumption of paper and paper board in India is low compared to the developed countries like US (350 kg), China (58 kgs), Japan (225 kgs) and world average 55 kgs however the total quantity of paper produced in India is quite significant with a total production of nearly 70 lakh tonnes per annum.
Indian handmade paper industry contributes to less than 0.5 % of the total country’s production of paper and paper board till the year 2005-06 and this share has recently increased to nearly 0.7% in the recent year since the production of handmade paper which was nearly 25,000 tonnes in the year 2005-06 now stands at nearly 50,000 tonnes. Although, the country is self sufficient in the manufacturing of handmade paper & board, however, a little quantity of specialty paper are imported.

Indian handmade Paper Production Cluster:

Kalpi – Uttar Pradesh
Sanganer – Jaipur Rajasthan
Kurukshetra – Haryana
Pune – Maharastra
Mehboob Nagar & Kareem Nagar – Andhra Pradesh
Karnataka
Tripura
Gujarat

Achievement of Handmade Paper Industry

In 1953 this industry was having 35 -40 units for production but today after half century hand made paper industry is having more than 3000 production units and increase of 35 times (1991 Rs 6 millions to Rs 210 millions in 1999-2000) recorded in hand made paper industry and its value added items. The  Handmade Paper Industry has provided gainful employment to around 18000 direct and indirect people today. Rural artisans are benefited through this industry.
The handmade paper units are scatter throughout the country with concentration most in the Kalapi (Jhansi, Uttar Pradesh), Sanganer (Rajasthan), Pune (Maharastra), Kurukshetra (Haryana), Mahaboobnagar (AndhraPradesh) and some clusters are in West Bengal. The production capacity of the units ranges from 50 kg to 700 kg per day. Kalapi is main cluster of  handmade paper production and its value added products. This cluster has more export oriented units. Today more than 60 production units are working. Registered institutions, co-operative societies, entrepreneurs and individual artisans are running their units. The capacity utilization of Handmade Paper Industry stands at 60-62 percent.

Before 1991, the industry was heavily dependent on captive market i.e. supply to State Govt. and Central Govt. departments against reservations.The shift started taking place in this scenario after 1991-92.
 There has also developed the non-captive market which can be classified into institutional and non-institutional. Institutional market demands bigger quantities while non-institutional smaller.  There are the eco-conscious buyers who purchase environment friendly produces like handmade paper and products for greeting cards, invitation cards, album, wedding cards etc. The market of carry bags is also growing steadily due to the ban on polythene bags.This changed situation has resulted into enhancement in capacity utilization, product diversification, culture of competitiveness, better management and market approach

Handmade Paper units growth in India:

Years	No. of working Units	Production Rs. lacs.
1953-54	40	5
1960-61	108	24
1970-71	176	81
1990-91	325	853
2000-01	2519	12101
2001-02	2641	22326
2005-2006	3260	53456

Market of Handmade Paper

The handmade paper industry has its own reputation for craft paper as well as its converted products. Some HMP products  have very god demand in the market like carry bags, albums, stationery items, gift items, packaging items, drawing papers, greeting cards, invitation cards, business cards, miscellaneous fancy and decorative items etc. The drawing paper produced by industry has a unique demand. The hand made paper industry is having a demand of 10,000 to 12,000 tones per year. The major consumers of handmade paper are, Govt. Offices, Hotel Industry, Publishers, Printing Press, Craftsmen, Export Agencies, etc. After survey in the potential consumes of handmade paper fallowing factors have came through this industry can increase its market demand for domestic market like Price, Shades/colors, Craftsmanship, Style, Trade visibility, Feasibility, Eco-friendliness etc

Handmade Paper Products

Paper Diaries,Paper Journals,Paper Envelopes,File Covers,Greeting Cards,Paper Books,Paper Notebooks,Invitation Cards,Paper Calendars,Letter Pads,Gift Wraps,Art Portfolios,Calligraphy Paper,Drawing Paper,Origami Papers,Pen Holders,Card Holders and Magazine Stand

Marketing of Handmade Paper

The marketing of handmade paper is different than any other goods and products. In spite of, so many qualities and attraction could not reach at the optimum level of its market share. Still in this global era the handmade paper industry does not have systematic and planned marketing strategies for its promotion at a wider level. The wide publicity about the use of handmade paper and its promotion activities will surely increase its acceptability and people habit to use it frequently. It has cyclical effect on the overall industry like acceptability increases its uses or demand which leads to more employment generation as well as increase in the income level of factors of production. The cost of production will  be decreases because at large level of production industry can obtain large production economies and technical up-gradation in the product and this  will certainly increases quality of product. In this present scenario customer are more quality conscious. Industry must know the customer's preferences, their perception about the products and its uses. In customer survey we have got few factors which influence the consumer's behavior for handmade paper products:

1. Quality of products
2. Price
3. Multiple uses
4. Availability
5. Durability
6. Advertisement and awareness
7. Substitute goods etc.

The handmade paper industry can produce variety of papers and its value added products but due to lack of awareness the demand of all varieties is not sufficient at various stages.  Many countries like Philippines, Japan, Korea etc are producing handmade paper in different varieties on the basis of colors, shades, thickness, smoothness, size etc. To the limited extent the people are recognizing this paper for eco-friendliness.

HISTORY OF HANDMADE PAPER

Handmade paper

Handmade paper is a layer of entwined fibres held together by the natural internal bonding properties of cellulose fibres by hand, sheet by sheet on moulds in suspension of fibres in water with or without sizing.

The history of paper dates back to the history of human culture and civilization. The Egyptians, Greeks and Romans wrote on “Papyrus”, a paper – like material. Today’s kind of paper was first developed and used in China. Since its birth the paper was the most important carrier of information in the past. Growth of population and need to transfer the knowledge, education and information to the society at large were the forcing factors for stupendous increase in the production of paper. In former times paper was a valuable product and paper making an art – that was often kept secret because of the outstanding advantages of the product.

Ever since man has been on earth he has made use of the materials around him. As numbers increased the need to communicate became apparent and language was born. Inevitably people began to look for ways both of preserving their ideas and culture and of passing information to others without having to meet face to face. The written word had arrived. The Egyptians started with papyrus in 4000 B.C. but true paper made from indivudual fibres did not appear until about 105 A.D. when the Chinese made some from mulberry flex, hemp and cotton, Tsai Lun who made paper from mulberry is considered the father of paper. However there archeological evidence shows that people were writing letter in India on paper made from cotton that has been well beaten together in 327 A.C.

Indian handmade Cluster

Kalpi – Uttar Pradesh

Sanganer – Jaipur Rajasthan

Kurukshetra – Haryana

Pune – Maharastra

Mehboob Nagar & Kareem Nagar – Andhra Pradesh

Karnataka

Tripura

Gujarat

INDIAN HANDMADE PAPER AT A GLANCE

Indian Handmade Paper

The handmade paper making in India goes as far back as to the 3rd century BC. Handmade paper making is a traditional art that has been practised by a particular class of people for generations together. This art has been passed on from one generation of craftsmen to another. These craftsmen are known as "Kagzi's". Their name is derived from the Urdu word 'kavas', which means paper. The size of this community has dwindled over the years. There is a small settlement of 'Kagzi's' in Sanganer near Jaipur, where a section of this community settled thousands of years ago. They claimed that they were originally from Turkey and from there moved to China and then finally settled in India.
In Sanganer the 'Kagzi' community is the primary owner of the handmade paper industry in the town. Their history goes back to the 14th century when the ruler was Feroze Shah Tughlaq. Even in those days the royalty used handmade paper made by them for official documents, miniature paintings, calligraphy, and to make copies of the Holy Quran and to maintain account books. In the 16th century the then ruler of Amber, Raja Man Singh brought the Kagzis to Sanganer and settled them on the bank of the river Saraswati, where clean water was easily available. Thus the town emerged as one of the biggest paper producing centers in north India.
With a long history of royal patronage, Jaipur has an impressive tradition of craftsmanship that produces the most extravagant goods for everyday uses – whether gold and silver jewellery, decorative textiles, brass and silverware, leather goods, or even handmade paper. We decided that paper – given the importance of stationery in our lives – would be an interesting topic to explore, so we set out on a trip to Kagzi paper production factory, which began its life producing paper for use in the royal court, and now produces for both the domestic and global markets. During this brief tour of their facility, we learned about the history and methods of traditional papermaking in Jaipur.
We were surprised to learn that this method of papermaking was brought to India during the 16th century by invaders from Central Asia. In prisons in Bokhara and Balkh, Chinese inmates had already demonstrated their skill in producing paper from natural waste. The fact this paper proved to be strong, durable and resistant to alteration or forgery, and could be produced in large quantities, led Babur – the first Central Asian invader to settle down in India and create what came to be known as the Moghul Empire – to encourage some of his men to learn this skill from the Chinese prisoners for use by the Moghul court in India. All court papers came to be prepared on the paper so produced as also, gradually, manuscripts and other related articles used by the educated citizenry. Prior to this introduction of paper, writing in India was carved on stone (e.g., Emperor Ashoka’s edicts), handprinted or painted on fabric (e.g., pattachitras), or etched on palm leaves (e.g., Hindu and Buddhist manuscripts).
The present-day Kagzi family in Jaipur (the name kagzi itself means “paper maker”) traces itself back to the settlers who travelled to India with Babur’s army and who had learnt the craft from the Chinese. Papermaking requires an unlimited supply of water and solid raw materials. Initially located in the district of Alwar (a little south of Delhi, in present day Rajasthan), the Kagzi family moved to Jaipur when water in Alwar became a scarce resource. They were also encouraged by an invitation from the kings of Jaipur who promised them court patronage and an abundant supply of water (the Dhundar region of which Jaipur is a part has always been a well watered one). The kings of Jaipur had entered into an early peace treaty with the Moghul court of Delhi, which resulted in a considerable amount of cultural exchange between the two kingdoms.

The Handmade Papermaking is a traditional industry of India. Innovation of papermaking was taken in 105 AD by China but there is a controversy on that issue. However, recent researches have given credit to India for this innovation of Paper from cellulose fiber even in third century B.C. The Handmade Paper Industry has been recognized as traditional craft of village industry under Khadi & Village Industries Commission (KVIC) Act-1957". KVIC provides special assistance to this industry for the development of rural craft and artisan work. In India it has been developed as cluster based industry.
 The most effective clusters are situated at Kalapi(Uttar Pradesh), Sanganer in Jaipur(Rajasthan), Mahaboobnagar( Andhra Pradesh) Pune (Maharasthra) Kurukshetra (Haryana) and Gujarat.Apart from these clusters there are some small clusters spread in all over India.

The KVIC has developed separate programme for Handmade Paper (HMP) industry during last fifty years in the association with Khadi and Village Industries Board and other Khadi Institutions.

Development of Handmade Paper Industry by KVIC

Initial Phase-I
A period of 1925-1953 &1955-56 is the first phase of development of Handmade Paper Industry. In the first phase KVIC itself was established by Govt. of India. The main objective of Phase-I was providing assistance to traditional kagazis (Traditional Paper Maker) in different production areas of Handmade Paper. In that period industry has small size of production and sales. The numbers of production units were less than forty and employees were not more than one thousand. It was era of craft, and that's why the industry became popular in next phase.

Pro-Phase-II
The second phase is a period of 1956-57 to 1966-67. In this phase Handmade Industry has got better position in production. The cooperative societies and registered institutions entered in this field through KVIC and KVIB's assistance programe. In this phase the numbers of units were increased. Production was more than rupees 39 lacks and employment generated five times as against first phase. At the end of this phase the actual numbers of working units were 149 and annual installed capacity was 3870 metric tons. It was the age of development in this phase all kagazis and artisans were motivated for producing craft paper and they innovated the different types of handmade paper using botanical fibers.

Middle Phase-
Since 1967 -68 to 1991-92 We can divide it into three phases. The period of 1967-68 to 1976-77, 1977-78 to 1986-87 and 1987-88 to 19991-92 were III, IV & V phases respectively. In all the above phases hand made paper industry was flourished and got good sales position. In the period of 25 years (1967-1992) of development the size of industry became large, more than 350 production units were established in India in different states and 7000 employees / workers directly and indirectly involved in to this.

Liberalization Phase-
The sixth phase of development was the period of 1992-93 to 1998-99. This was an age of accelerated growth of individual and private entrepreneurs. In this phase KVIC and other developmental agencies concentrated on research and development of hand made paper industry. In this era KVIC started survey and study of international market and domestic market and organized workshops, seminars and exhibition of hand made products. Government of India organized UNDP project on this industry titled Strengthened the handmade paper industry in India (1991-98). UNDP-KVIC-Project emphasized at consumer behaviour and value addition in hand made paper industry. At the end of sixth phase this industry had more than 415 production units in India and the production grown up to Rs 30 carores and generated employment for 10,000 skilled and unskilled people.