ITC Bhadrachalam Paperboards Limited initially operated a paper/paperboard manufacturing plant with a capacity of 300 Tons Per Day (TPD) located in Sarapaka near Bhadrachalam, Andhra Pradesh. To expand its operations, the company embarked on a strategic plan to enhance the existing facility. The expansion involved the installation of a cutting-edge paperboard machine with a capacity of 550 TPD, complemented by a co-generation plant generating 21 MW of power.

The manufacturing process included multiple formation units, energy-efficient presses, and cylinder drying. Surface treatment comprised a machine glaze cylinder, size press, two-stage online coating, and soft calendaring, all integrated into an automated system.

Tata Consulting Engineers (TCE) played a pivotal role as consultants, providing detailed civil engineering and piping design for various components of the expansion project, including Paper Machine IV, wastepaper pulp plant, broke and fibre recovery, coating kitchen, additive preparation building, finishing house, and compressor house. The entire project aimed to significantly boost ITC’s annual production capacity from 62,500 Tons Per Annum (TPA) to 1,82,500 TPA. The trial production of the new plant commenced in October 1997, marking a substantial milestone in the company’s growth and productivity.