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| Chairman's Speech (ITC Bhadrachalam) | Year : Mar '95 |
I extend a very warm welcome to all of you at this 19th Annual General Meeting of your Company. During the past year, there was a Changing of the Guard on your Board. Mr. K.L. Chugh, who had been the Chairman of your Company since August 1989 and Managing Director of your company for nearly eleven years prior to that, stepped down from the Board with effect from May 5, 1995. Mr. Chugh has indeed played a distinctive role throughout the formation, stabilisation and growth phases of ITC Bhadrachalam Paperboards Limited. On behalf of all of you, your Board of Directors, the Employees and all other Stakeholders of your Company, I would like to place on record my most sincere appreciation of his invaluable contribution to your Company's growth and market standing. Mr. F.R. Vevaina, who was a Director of your Company for a period of over 9 years, also stepped down from the Board during the year. I would like to thank him most profusely for the valuable contributions made by him. I joined the Board of your Company on October, 19, 1994 and was elected Chairman with effect from May 5, 1995. I seek your good wishes and look to your support and encouragement in the discharge of my new responsibilities. The signing of Gatt and emergence of the World Trade Organisation have commenced the process of dismantling trade barriers and spurring international trade. Global priorities are shifting from political concerns to economic agenda. Our economic liberalisation programme, which commenced four years ago, has also brought us progressively into the mainstream of international economic activity. We have quite suddenly been brought face to face with direct international competition. Since the last Annual General Meeting, import duties on paper and paperboard have been dramatically slashed from 65% to 20%. This has given rise to a paradigm shift in the fundamentals of competitiveness for the Indian Paper Industry. Our Industry now has to gear itself up with utmost urgency to be able to compete effectively on the international stage. To put it simply, even to survive, let alone grow, we have to become world class. The Indian Paper Industry, in particular, has a multiplicity of issues to contend with, making its task even more arduous. I propose with your kind permission, to dwell on some of the major global trends, before addressing the key issues of competitiveness facing us. GLOBAL TRENDS IN THE PULP AND PAPER INDUSTRY Global demand for paper and paperboard is expected to grow annually by 2% at least in the next decade. A 1994 FAO forecast projects world paper production capacity expansion from 290 million tonnes in 1993 to 320 million tonnes in 1998, with demand for paper products increasing from 249 million tonnes to 292 million tonnes in the same period. India's current working capacity at around 2.8 million tonnes, and production at 2.4 million tonnes, accounts for a bare 1% of global demand. While the global paper capacity is slated to increase annually at 2%, the world pulp production capacity is projected to increase annually at only 1%. The primary cause for this mis-match is the projected scarcity of pulp-wood on account of harsher environmental laws restricting the felling of trees. Further, a combination of environmental, social, technological and economic factors is encouraging increased recovery and usage of waste paper and other recycled fibres in global paper production. The share of recycled fibre in the typical paper furnish in some developed economies has already increased from 25% in 1980 to 35% in 1993 and is expected to exceed 40% by year 2000. Despite the technological breakthroughs enabling greater use of recycled fibre, shortage of virgin woodpulp is likely to escalate. There is also a perceptible trend in the growth of pulp production capacity shifting from countries in the Atlantic Rim to the tropical countries such as Indonesia, Thailand, Australia, Brazil and Chile. Indonesia has now become the world's lowest cost producer of pulp with a 1994 variable cost estimated at 7 per tonne, followed by Brazil at 1 and Canada at 1. The harvest cycle (from growing to cutting) for tropical hardwood plantations such as eucalyptus is shorter at around 7 years, compared to over 30 years for softwood trees. Indian soil and climatic conditions are also fortunately conducive to hardwood plantations, with relatively shorter growth cycle. The apprehended scarcity of raw materials is spurring application of biotechnology towards improved plantation yields and development of alternative sources of raw materials in keeping with intensifying ecological concerns. The concomitant trend of increased use of recycled fibre has also accelerated the development of innovative and efficient technologies, associated with de-inking, chlorine-free bleaching and process control equipment used to separate different fibre fractions. Such trends and developments have altered the sources of competitive advantage in the manufacture of pulp, paper anti paperboard in a globalising market. Availability of cost-effective raw materials, efficient energy management, access to sustainable technology for quality and cost competitiveness and compliance with ecological demands now constitute the critical success factors. INDIAN PAPER INDUSTRY -- PRESENT POSITION Demand for Paper and Paperboard Per capita consumption of paper and paperboard in India at 3 kg is presently amongst the lowest in the world, against a world average of over 45 kg with 315 kg in the USA, 225 kg in Japan, 218 kg in Singapore and 18 kg in China. With increasing literacy, accelerating economic and industrial growth and rising per capita income, India will be one of the fastest growth markets in the next decade. A United Nations study has concluded that elasticity of paper demand in countries with low per capita incomes, ranging between 0 and 0, is higher at 1.5 to 2.5. This translates to a growth in paper demand in our country of around 8% per annum. In quantitative terms, this implies an increase in paper and paperboard demand from the present 3 million tonnes to 5 million tonnes by the turn of the century. The income growth and distribution pattern in our country -- with faster growth being exhibited in the middle and upper classes -- will result in a more rapid growth in the industrial packaging paper segment, at around 12%. This augurs well for your Company, being the market leader in this segment. There is also a perceptible qualitative shift in the demand towards paper and paperboard of higher strength and better surface quality. Consequent to the economic liberalisation, international quality benchmarking has become more of a rule than an exception. Production Capacity & Industry Structure The Indian paper industry today comprises 379 mills, of which 150 mills are reportedly lying closed, resulting in a net operational installed capacity of 2.8 million tonnes, excluding newsprint. A few large sized forest-based mills, including that of your Company, account for over 40% of the total installed capacity. The remaining mills are agro-residue and waste paper based. Most of these mills are performing poorly due to erratic availability of raw materials, lack of chemical recovery facilities, irregular power supply, higher financing costs, use of absolete technology, and inadequate scale economies. INDIAN PAPER INDUSTRY -- ISSUES OF COMPETITIVENESS The key issues of competitiveness facing the Indian Paper Industry are raw material competitiveness, energy competitiveness, technology upgradation and economies of scale. Government policy in the 1970s and 80s encouraged the setting up of smaller mills through fiscal support and easy import of second hand plant & machinery. The fragmented structure of the industry evolved thus in a closed and regulated regime has now rendered many of the mills uncompetitive in an open and globalising economy. The restructuring of the industry will not be painless and will require imagination, will and, above all, a policy framework that takes into account the requirements of transition. Fibrous Raw Materials -- Availability and Competitiveness The most critical issue facing the Indian paper industry is the availability of cost-effective fibrous raw materials. Creation of paper manufacturing capacity, based on straw, has not kept pace with the growth and pattern of demand of the Industry. This is due to the cumbersome and uneconomical task of collection from widely dispersed areas, the attendant problems of storage of this seasonal product, and prior charge on straw for cattle feed, limiting the size and induction of appropriate technology on the one hand, and non-availability of suitable sites for installation of paper mills, in some other areas, where straw is available, on account of non-availability of water, problems of disposal of effluent, availability of power and coal, on economic basis, on the other. The potential of straw, as a major source of raw material is, therefore, likely to remain limited. Bagasse was considered in the 1970s to be a promising alternative to forest-based raw materials. This has, however, not fructified to the extent expected. Sugar mills are reluctant to convert their bagasse fired boilers in view of the problems of coal availability, additional capital investment and increased cost of steam and paper. The emerging pattern of demand and requisite parameters of strength and functionality, in various grades of paper, limits the use of bagasse as universally accepted raw material for all grades of paper. Availability of bagasse, in sufficient quantity, on a sustainable basis, at such sites which are suitable for manufacture of paper, does not appear to be promising. The collection and recovery of waste paper in India is largely unstructured and likely to remain so in the foreseeable future. The availability of waste paper in our country is also limited because of its other varied uses. The rate of reclamation is barely 1.5% compared to around 40% in the developed countries. Industry requirements are therefore being supplemented substantially through imports and such reliance on imports will continue. This, however, will be feasible only by those mills that produce specific grades of paper and paperboards and have advanced recycling technology. There has been a chronic shortage of forest-based raw materials, viz. bamboo and pulpwood. The shortage is likely to escalate with dwindling forest cover. Though the National Forest Policy of 1988 specifies 33% forest cover for ecological balance, the actual forest cover is barely 11%. Despite various form forestry and revegetation programmes, population and industrialisation pressures have led to a progressive depletion of forest cover. The present domestic pulpwood availability is insufficient to meet requirements, and imports are relied upon to meet the shortfall. India consumes roughly 170 million tonnes of wood each year, of which over 85% is firewood and barely 2% is pulpwood; the remainder being used as timber. It is estimated that if paper industry's entire requirements are to be met domestically, pulpwood availability has to more than double to 7.2 million air dry tonnes by year 2000, and grow further to 12 million air dry tonnes by year 2015. While the larger issue of forest cover does need urgent attention, the visible impact of any related policy measures would take decades to manifest itself. The issues related to pulpwood for Paper Industry are relatively more manageable in the short to medium term, and need to be dealt with in their own right, delinked from the larger issue of forest cover. The National Forest Policy of 1988 does not permit industrial plantations on forest lands by the corporate sector. Equally, farm forestry by the corporate sector is not feasible due to land ceiling regulations, thus making the industry dependent on individual farmers. Individual land holdings are small and fragmented, rendering cumbersome the logistics of financing, technology application and collection. Farm forestry programme instituted by paper mills have met with limited success. According to estimates of The Wasteland Development Board, degraded land accounts for 130 million hectares out of a total 329 million hectares. This comprises 30 million hectares of degraded forests and 100 million hectares of agricultural and non-forest waste lands. Pulpwood yield from plantations is generally 10 times that from natural forests. Paper industry would be in a better position to secure its pulp requirements indigenously, if even a small portion of the large area of degraded forest lands were to be made available for plantations by the corporate sector. I would strongly urge amendment of policy to enable allotment of adequate degraded forest land in contiguous blocks in proximity to the mills for the corporate sector to develop technology led plantations. Adequate safeguard could be incorporated to ensure that the corporate sector does not assume any de facto ownership of such land. Such a scheme, apart from enhancing competitiveness of the Indian paper industry, will yield multiplier benefits in terms of improving ecological security, providing gainful employment, and conserving foreign exchange. Energy Management Paper Industry is one of the most energy-intensive, with energy cost comprising 20-25% of the cost of manufacture. The average energy wastage in Indian mills exceeds 35%, compared to the international average of 20%. Effective energy management is, therefore, critical to cost competitiveness. Indian paper mills on an average consume 70% more thermal energy and 110% more power per tone of paper produced than their international counterparts. The main reasons are systemic in nature, attributable to the poor and variable quality of coal, erratic and poor quality power supply, and the more onerous process requirements for the types of raw materials used in India. Moreover, small mills cannot generally afford captive co-generation systems and use either DG sets or purchase their entire power requirements from the erratic State grids, thereby increasing their energy cost per unit of production. These systemic inefficiencies are likely to be resolved in a hurry, and will have to await fructification of reforms in the power sector. The larger integrated paper mills in the country are, however, in a better position to overcome the systemic disadvantages through investment in appropriate technology suited to the quality of coal available in India. They are also in a position to realise the economies inherent in captive co-generation systems, thereby fully exploiting the cost advantages of cheaper coal. Large mills should be encouraged to invest in economically sized captive power generation units through a policy framework that would permit sale of surplus power to the State grids on commercial terms. Secondly, though the development of fluidised bed combustion technology in recent years has facilitated the optimum utilisation of low colorific, high ash content coal, the disposal of the resultant ash continues to dodge a solution. Till such time a lasting solution is found to utilise such solid waste in a viable manner, the State Governments need to provide land to the paper mills for ash disposal, just as land for ash ponds is provided to power generating units. Technology Upgradation and Economies of Scale Paper industry is highly capital-intensive and normally located close to one or more of its critical inputs such as raw materials, coal and water. Such locations are usually in the backward areas. Apart from investment in the mill, substantial capital is employed in attendant infrastructure relating to health, education, housing, transportation and communication facilities required to supplement the infrastructure provided by the State. This renders the enterprise even more capital-intensive. International competitiveness requires application of state-of-art technology to enhance utilisation of raw materials, improve product quality and simultaneously meet the most stringent standards of pollution management. Such technology is expensive and can be made viable only through achieving economies of scale. Escalating capital costs have made greenfield investments prohibitively expensive. The answer to competitiveness in Indian Paper Industry therefore lies in the scaling up and modernisation of existing mills, thereby more fully exploiting the existing infrastructure and facilities. The urgency of this task cannot be overemphasised and will require both entrepreneurial will and the application of managerial resources, time and money. Only the nimble-footed will survive the next downturn in the international paper markets when the severity of international competition in its real form would more fully impact the Indian market. The capital intensity of this industry and the relatively higher interest rate structure in our country also call for innovative financial restructuring with increasing emphasis on equity financing to ensure that the burden of capital intensity is managed effectively. MANAGING TRANSITION -- IMPORT TARIFF STRUCTURE Prior to the commencement of economic liberalisation, the tariff structure insulated the Indian Paper Industry from international competition. Import duties were as high as 140% in 1991/92. These were scaled down in a phased manner to 65% in 1994/95 and thereafter drastically reduced to 20% in two quick steps, while the customs duty in most other cases was brought down to only 50%. This sudden drop in import duties on all varieties of paper has indeed taken the Indian Paper Industry by surprise and rendered it uncompetitive based on fundamentals. Fortunately, the international market is on a rapid upswing with international prices of bleached softwood pulp having risen from US0 per tonne towards the end of 1993 to US70 per tonne in March, 1995. Paper Industry being cyclical in nature, the next downturn can cripple the Indian Industry through large scale imports of prices that the Paper Industry in its current form will find difficult to withstand. Whilst the Indian Paper Industry needs to address issues of competitiveness which of necessity would take time. The import tariff structure, therefore, should take into account the needs of transition. The precipitous drop in import duties was caused by a temporary shortage in the cultural segment, which was further aggravated by the diversion of creamwove paper to the newsprint industry. Quite clearly, a temporary supply-demand imbalance in the cultural segment justifying a tariff reduction intervention, neither warrants its long term continuance nor its uniform application to other paper segments. The uniform application of customs duties across all paper segments is not justified. The Government needs to take a pragmatic view on each major product segment of the paper industry, and accordingly calibrate the tariff structure. The reduction in import duties of paper products should go hand in hand with a reduction in duties on inputs. I would, therefore, recommend that import duties on pulp and wastepaper be completely withdrawn and duties on other consumables and chemicals reduced substantially so that value addition on our shores can become a sustainable and growing economic activity. COMPETITIVE STANDING OF ITC BHADRACHALAM Your Company has always been cognisant of issues of global competitiveness and is engaged in taking urgent steps in this direction. The bio-technology based R&D programme for genetic improvement of planting stock of eucalyptus through clonal technology has enabled development of fast growing, high yielding and disease resistant clones for large scale commercial plantations. The demand for these saplings from farmers and the State Forest Departments is growing rapidly. Your Company continues to invest in this long gestation activity to secure long term availability, quality and cost effectiveness of pulpwood in the command areas of the mill, and to enable future scaling up of mill capacity in keeping with evolving global standards. Your Company has commenced the first phase of a massive modernisation and expansion project at a capital cost of Rs.525 crores. The successful completion of this project will more than double its capacity and is expected to render it internationally competitive. The project includes installation of an atmospheric fluidised bed combustion boiler and a turbo-generator of matching capacity with condensing facility that will enhance energy self-sufficiency and cost competitiveness. The project is being funded by utilisation of the proceeds from the earlier rights issue in 1993, tying up of debt and a proposed equity issue sometime later in the current fiscal year. A large complement of the Mill's workforce is drawn from the backward tribal area. Your Company has always been committed to the education, economic and social advancement of the local population. The induction of state-of-art technology requires time-consuming re-training and HRD inputs. The continuing attention given by your Company to training and HRD has paid rich dividends and I am confident that the new technology would be effectively absorbed. The times ahead are therefore indeed very challenging for your Company. I am sure that with your support and encouragement, your Company will grow from strength to strength. I thank you for your kind attention. |
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| Source : Dion Global Solutions Limited | |
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