SANJAY YADAV

Experience

• 

  BILT

  Jul 2000 - Sept 2006

  Assistant Manager R&D/QA

  Significant Achievement • Honour of being awarded with A rating & cash reward for continuous two years in annual appraisal• Actively involved in the process of Kraft Pulping, proximate analysis and C/DEopD1D2 bleaching of various wood (Acacia, Radiata pine, Poplar, Babul, Veneer waste & Eucalyptus) and non-wood (Bamboo, Kahi, Bhabbar and Bagasse) fibrous raw material. Successful plant trial of mix hard wood of Eucalyptus, Poplar Veneer waste & Bamboo. Effectively increased the packing density in digester to get max pulp from one cooking.• Worked on project for reducing the soda loss by 20% resulting in reduction of chlorine & chlorine di oxide consumption and thereby AOX level in effluent• Worked with team for development of Matrix paper for stationary pads and printing, Coating Base Paper, CIS & C2S paper for posters, labels and magazines & Coated Art Board (black centered board) for playing card segment. • Pivotal in printing evaluation of different coated paper for improving the quality of coated paper. Print Gloss was increased by 5-8% in all of the varieties through coating formulation optimization. • Effectively optimized Coating Color recipe for making Chromo paper, art paper and coated board for Blade Coating during commissioning of blade coating plant. • Managed various projects for improving the coated paper quality as per customer requirement and also developed alternative vendors for chemical based on R&D performance test and implemented in plant with cost saving benefits. Effect of Clay: GCC ratio in coating on surface, optical & printing properties. Show less

• 

  Trident Paper

  Sept 2006 - Oct 2013

  R&D/QA Head

  • Product stabilization of Copier and Non-copier varieties on New Paper Machine#2 • Credit of being awarded with Cash Reward and Exceptional Growth for significant contribution in Fiber Loss and increasing % Ash• Played a vital role in developing:o Surface sized Maplitho products having different brightness, bulk, shade and smoothness.o Copier Paper in 70, 72, 75 and 80 GSM and Copier Paper for US market.o Stiffener paper for Soap Wrapping.• Replaced Basic dye with Pigment dyes at both the machine in order to get Good Light Fastness and reduce shade variation complaint.• Implemented the QMS, EMS and OHSAS for Certification of ISO 9001, ISO 14001 and OHSAS 18001 from Det Norske Veritas (DNV). It has also revised as per New Standard and further extended to three years.• Successfully managed process parameter optimizing during commissioning of new paper plant such as o Refining of hard Wood/Soft Wood/Wheat Strawo Sequencing of Wet-end Chemicals o Deg SR of stock in Head Boxo Cationic Charge Demand o Loading at Press and Calendar section in different variety of products o Size Press pick up through Film Size press (A-Sizer) and % solids of Starch• Successful implementation of AKD Sizing in place of Acidic Sizing at PM#1 and AKD Sizing at PM#2. Two papers are also presented in IPPTA Workshop.• Replaced Soap-stone filler with GCC-10 that resulted in increasing the brightness of paper and inturn High Bright product development.• Standardized the procedure of cooking the Cationic starch and Oxidized starch. This has resulted in reducing the dust/fluff in Maplitho Paper.• Optimized bleaching sequence parameters for Chlorine di oxide to increase the ISO Brightness by 1.5%• Increase the reduction efficiency of Bio-methanation plant and efficiency of primary clarifier to reduce the outlet COD by 15%. Show less

• 

  Century Pulp and Paper

  Oct 2013 - May 2015

  GM (R&D/QA)

  Significant Achievements • Quality improvement in Maplitho paper with respect to Bulk, Smoothness, Shade and Opacity. Devise the culture of Product profitability. New product development in Maplitho, Overlay tissue, Absorbent pink paper for mosquito repellent and 70 GSM Copier Paper/High strength towel Tissue, color tissue and Unicharm Carrier tissue/Deck card for playing card, Grey Back and other VAP Board through structured manner.• Stabilized the Paper/Board/Tissue quality by eliminating the quality problems and established the quality check points.• Changes in Customer complaint handling procedure and developed the culture of assuring the quality through “I produce I assure” concept. It has resulted in significant reduction in Customer Complains and gaining the customer confidence in quality.• Introduced WGCC in place of Soap stone for improving the quality with respect to opacity, brightness and cutting quality.• Introduced permanent pigment dyes in place of basic dyes to reduce shade reversion and increasing the whiteness.• Optimize surface size formulations for enhancing the printability. • Evaluation of Raw material furnish for Alkali requirement, Yield and pitch content. This study used in fixing the raw material furnish for reducing the pulp cost and improvement in quality. • ISEGA for Board and PREPS three star for Paper/Board certification. Show less

• 

  Trident Group

  Jun 2015 - May 2016

  VP (R&D/QA)

  Significant Achievements • Development of Digital paper.• Patent file on new product by following structured approach for novel invention.• Resolution of dusting complaint through input and inprocess analysis.• Setting up specification for Wet PCC and GCC. • Introduced new test for Powder GCC to check quality to correlate with paper performance at customer end.

• 

  Century Pulp and Paper

  May 2016 - now

  Heading strategy and development for business growth after successful leading Operation team (700+) as Head Process of Paper/Board/Tissue Manufacturing Process with Engineering function. With this , I went through Exposure and Experience in manufacturing process of Paper Grade Pulp (Agro/Wood/Waste Paper DIP/Unbleached Kraft pulp/OCC waste), RGP, Paper, High BF Kraft Paper, Absorbent Kraft Paper, Tissue, Coated Paper & Packaging Board (C1S, C2S, Art Board, Grey back, White back, White Kraft liner, FBB and SBS) along with Recovery and ETP through systematic process control to achieve productivity, cost & delivery through OEE & People processes in safe working environment. With this , I have enriched my skills to contribute in operation in any scale to lead the team for improving productivity and efficiency with cost saving measures through effective utilizing the resources and maximizing team output. Show less Lead Manufacturing process of Seven Machines (4 Paper machines, 2 tissue machines and 1 four-layer Board Machine) through cost effective production by estimating costs, monitoring of production processes, maintaining Health/Safety/Quality guidelines and adjust schedule as needed. Main achievements were-• Erection and Commissioning of Shoe press to increase production from 50 tpd through speed increased by 100 mpm, % Dryness after press increased by 3-4%, 50% reduction in no of breaks and 15% steam reduction.• Modification of rewinding slitting station to speed up rewinder. It has resulted in 200 mpm speed increase.• Copier sheeting capacity increased by 30 tpd through de-bottlenecking.• Increase of wire life through process control.• Optimization of Refining system at two machines as per product requirement and increase of % moisture by 0.5%.• Stabilization of New tissue machine and completion of performance run to achieve 90% Efficiency.• Modification of slushing process of high wet strength broke to again reuse in paper making.• Commissioning of Steam profiler, Induction profiler, edge trim box and double doctoring on Couch to reduce 2 Sigma moisture from 1.5 to 0.5 and Uniform caliper profile. These initiatives helped in reduction of quality rejection and thus increase of production by 15 tpd and moisture increase from 4.5 to 5.0%. • Development of three new products under Unbleached grade , packaging grade and tissue grade.• Selection and Planning of New Head Box at Paper machines to increase production by 30 %. Show less Lead the team of 161 for New Product development and quality improvement through regular interactions with marketing/sales dept. as per changed Market dynamics. This is achieved through development and modification in Product recipes for product design and improvement in existing product with packaging development as per marketing guidelines. Apart from this , Identification & implementation of process improvements and Chemical optimization studies were done across the complete plant to increase the efficiency and effectiveness of processes. Major achievements were • 24 New products developed in Paper, Tissue and Board with product stabilization on New Extrusion coating machine.• Study of WGCC and its optimization with talc and PCC , Replacement of AKD Sizing with ASA for quality improvement.• Re-presentation in CII 7th Environment Summit at Haridwar and CII 3rd Water Summit on Pulp & Paper at Delhi.• Use of liquid oxygen in Unbleach and bleaching stage, Chemical optimization of Enzymatic starch (cooked by Jet cooker), Oxidized starch & fluff chemical. It has resulted in reduction of SW in Writing and Printing grade of paper.• Installation of On-site PCC plant and replacement of Talc and GCC with PCC as a filler to get the % Ash gain , OBA reduction and Opacity/Bulk gain. Show less

  • Head of Strategic and Development

    Apr 2023 - now

  • Head Process

    Apr 2022 - Apr 2023

  • Head R&D/QA/NPD

    Jul 2021 - Apr 2022

  • General Manager

    May 2016 - Jul 2021