ROADMAP FOR THE PAPER INDUSTRY IN PHILIPPINES (2014-2020)

_________________________________________

Ray N. Geganto

Exec. Director

Philippine Paper Manufacturers Association Inc. (PPMAI)formerly Pulp &Paper Manufacturers Assoc. of the Phils. (PULPAPEL)

The Phil. Paper Manufacturers Assoc. Inc. (PPMAI):(formerly Pulp and Paper Assoc. of the Phils.(PULPAPEL)

MEMBERS MILLSITE

1. Trust International Paper Corp. (TIPCO) Mabalacat, Pampanga

2. United Pulp and Paper Co. (UPPC) Calumpit, Bulacan

3. Bataan 2020 Inc. Samal, Bataan; Baesa, Q.C.

4. Container Corp. of the Phils. (CCP) Balintawak, Q.C.

5. Noahs Paper Mill, Inc. Marikina

6. Liberty Paper Inc. Valenzuela City

7. Paperland, Inc. Balintawak, Q.C.

8. Fiber Sorting Inc.

9. Asia Paper Ind. Corp.10.St. Thomas Paper Corp.11. Hansson Paper Phils. Corp.12. Vanson Paper Ind. Corp.

Pampanga

Trece Martires, CaviteSto. Tomas, BatangasPasig, NCRValenzuela, NCR

What is Paper and Paperboard?

Paper Industry in Phils. -Current State and Background

2001 2010 2012Est.

HistoricalTrend% p.a.

No. of Paper Mills 43 27 24

Industry Capacity, ‘000 Tons 1,580 1,297 1,200 -2.2%

Production 1,056 1,038 825 -2%

Imports 533 961 1,100 +9.5%

Exports 139 165 110 -2%

CONSUMPTION 1,450 1,834 1,810 +2.2%

Paper &Board per Capita Consumption

16 20 19 +2%

Paper Mills remaining in Operation (2012)

1. Trust International Paper Pampanga Newsprint, Printing &Writing

2. United Pulp and Paper Bulacan Containerboards

3. Bataan 2020 Bataan, Q.C. Pr &Wr, Containerboards,Bag paper

4. Container Corp. of Phils. Quezon City Containerboards, Cartonboard

5. Noahs Paper Mill Marikina Pr &Wr, Bag paper

6. Liberty Paper Valenzuela City Containerboards

7. Fiber Sorting Pampanga Cartonboard, Containerboard

8. Asia Paper Ind. Cavite Printing &Writing

9. Paperland / Valley Quezon City Cartonbd, Containerbd, Bagpaper

10. St. Thomas Paper Batangas Containerboard

11. Cascades / Malinta Cavite Containerboards

12. Multipack/Certified Mills Laguna Containerboards, Brown wrapping

Paper Mills remaining in Operation (2012)

13. Danao Paper Cebu Containerboards

14. Hansson Pasig Pr &Wr, Brown packaging paper

15. Hansson (Menzi) Bukidnon Packaging

16. Quanta Pampanga Tissue

17. Vanson Valenzuela Pr &Wr, Cartonboard

18. Fedco Laguna Pr &Wr, Cartonboard

19. Alliance Valenzuela City Pr &Wr, Cartonboard, Wrappings

20. Golden Swan Cavite Containerboard

21. Rosario Valenzuela Brown wrapping/packaging paper

22. Globe Paper Malabon Pr &Wr, Brown wrapping/packaging

23. Rural Paper24. World Class Paper

BulacanPampanga

Pr &Wr, Brown packagingPackaging, Printing &Writing

Paper mills Closed /Shutdown –from early 90’s-2011

1. PICOP Resources * Surigao Kraftlinerbd, NP, G’wood printing

2. SCA Hygiene Cavite Tissue and sanitaries

3. Kimberly-Clark Laguna Tissue and sanitaries

4. Paper City Valenzuela Pr &Wr, Cartonboard

5. Aclem Laguna Pri &Wr, Tissue, Brown wrapping

6. Manila Paper Mills Quezon City Pr &Wr, Containerboard, Wrapping

7. Sunrise Bataan Cartonboards, Containerboards

8. Dasmarinas Paper Cavite Cartonboards, Containerboard

9. East Asia Paper Cavite Tissue and Sanitaries

10. Arco Las Pinas Containerboard, Brown wrapping

11. Isopack Laguna Containerboards

12. Worldwide Paranaque,Q.C. Brown wrapping, Cartonboard

*Integrated Pulp-Paper Mill

PICOP Millsite in Surigao del Sur_____________________________________________

Paper mills Closed /Shutdown –from late 80’s-2011

13. Rustan Packaging *

14. Phil. Paper Mills

15. 3rd Wind Paper

16. Chanmeco

17. Asgard

18. Paramount

Iligan

Tondo, Manila

Pampanga

Valenzuela

Novaliches

Valenzuela

Cartonboards,Containerboard

Cartonboard, Containerboard

Tissue and Sanitaries

Containerboard, Cartonboard

Containerboard, Cartonboard

Printing & Writing, Brown wrapping

19. Fortuna Valenzuela Containerboard, Wrapping, Tissue

19. Prince / Sn Fernando Pampanga Printing &Writing

20. Oxford Paper Laguna Pr &Wr, Containerboard,Wrapping

21. PDM Laguna Specialty Paper

*Integrated Pulp-Paper mill

Pulp Mills in Philippines

In operation as of 2010: Site Capacity Product

1. Canlubang Pulp Laguna 3,600 Tons/yr Abaca Market pulp

2. Alindeco Albay 12,500 Abaca Market pulp

3. Specialty Pulp Manuf Leyte 12,000 Abaca Marketpulp

4. Pulp Specialists Inc. Leyte 5,000 Abaca Market pulp

5. Newtech Pulp Lanao 8,500 Abaca Market pulp

CLOSED / Shutdown from 90’s -2010

6. PICOP Resources * Surigao 110,500 T/yr Kraft,Mech’l pulp

7. Cellophil Resources Abra 65,000 Kraft Market pulp

8. Isarog Albay 9,000 Abaca market pulp

*Integrated to Paper mill.

THE PAPER INDUSTRY ALSO HAS CLOSE LINKAGES TO:

• Technical Association of the Pulp and Paper Industry (Tappi-Phils.)

• DOST – Forest Products Research and Development Institute

• DTI – Bureau of Product Standards

• DENR – Environmental Management Bureau

• Printing Industries Development Foundation

• UPLB College of Forestry and Natural Resources

Problems of the Pulp and Paper Industry in Phils.________________________________________

• RAW MATERIAL– Local wastepaper quality low (poor yield, inefficient operation)– Local wastepaper supply is inadequate (high price)– Imported wastepaper supply getting tight – No local source of pulp.

• HIGH COSTS OF ENERGY– Electricity (requires investment for lower-cost power and

energy-efficient technologies)– Fuel (requires investment to convert to coal, biomass and fuel-

efficient technologies)

Paper Industry Fiber Raw Material Demand

2010 2011

Wastepaper, Local-sourced 970,000 854,500

- White/Deinking grades 250,000e

- Brown/Packaging grades 604,500

Wastepaper, Imported 120,400 248,000

- White/Deinking grades 200,000e

- Brown/Packaging grades 48,000

Wastepaper Totals 1,090,400 1,102,500

Pulp (all imported since 2010) 67,250 49,820

Problems of the Pulp and Paper Industry in Phils. –2

________________________________________

• MANY PAPERMACHINES OLD AND SMALL– Small mills costlier to operate than bigger mills– Difficult to rehab, maintain, upgrade (frequent breakdown)– Some mills not originally intended to run on 100% wastepaper– Lack equipment to handle low-grade wastepapers.

• FLOODING OF DOMESTIC MARKET WITH IMPORTED PAPER– Tariff duties removed/minimized– Misclassification in imports– Low valuation of certain grades paper.

Problems of the Pulp and Paper Industry in Phils. –3

________________________________________

• ENVIRONMENTAL REGULATIONS GETTING MORE STRINGENT– Mills suffering cash flow lack low-ROI funds to install more anti-

pollution devices – Mills must invest in cleaner production technologies (expensive)– To improve environmental performance – need highly-technical

professionals or training for its personnel.

• SKILLED AND PROFESSIONAL MANPOWER DIMINISHING– Overseas jobs pull workers from paper industry– Other industries offering more attractive compensation– Fast turnover / high cost of training– Declining # of engineering graduates going to pulp and paper

industry.

PROPOSED SOLUTIONS AND LONG-TERM STRATEGIES _____________________________________________

• RAW MATERIAL– Limit export of OCC due to supply is inadequate– Invest on technologies that improve wastepaper

utilization– Establish local production of woodpulp (enable

existing paper mills to make higher-grade paper &board)

– Develop agri-wastes and annual crops as sources of non-wood fibers (supplemental virgin pulp for existing paper mills).

Recovery Rate of Selected Countries

Selected Countries Recovery Rateas of 2011

USA 66.8%

Japan 76.9%

World 57.2%

Malaysia 54.1%

Indonesia 53.5%

Philippines 49.9%

China 45.0%

Source : RISI World Pulp and Recovered Paper Forecast

PROPOSED SOLUTIONS AND LONG-TERM STRATEGIES -2

_____________________________________________

• HIGH ENERGY COSTS– Upgrade existing mills to energy-efficient

technologies

– Encourage investments in co-gen plants

– JV with new power projects

– Encourage investments in bio-mass and waste-burning power plants or boilers

– Support projects based on clean and renewable energy.

PROPOSED SOLUTIONS AND LONG-TERM STRATEGIES -3

_____________________________________________

• OLD AND LOW-CAPACITY PAPERMILLS– Projects and programs to improve tonnage and

productivity

– Retool or replace small machines to shift to higher-value paper products

– Make available local virgin pulp to reinforce low-grade recycled fiber and enable production of better-quality paper and board.

PROPOSED SOLUTIONS AND LONG-TERM STRATEGIES -4

_____________________________________________

• IMPORTED PAPER FLOODING DOMESTIC MARKET– Set up better controls vs. misdeclaration of

imports

– Defer further reduction of remaining tariff duties on paper and paperboard

– Help existing mills establish capability to make higher-grade paper products.

Paper products we should make

PROPOSED SOLUTIONS AND LONG-TERM STRATEGIES -5

_____________________________________________

• ENVIRONMENTAL ASPECTS– Incentives for investment in clean technologies

– Support for upgrading wastewater treatment plants and new pollution control devices.

• MANPOWER ASPECTS– Support for training and manpower development

programs, esp. intended at improving process efficiencies and environmental performance.

Market Growth by Grades of Paper/Paperboard

2011 Local Product-

ione

Imports Total Market

SegmentShare of Market %

ProjectedGrowth

(2011-2016)

Printing &Writing 260,000 196,400 456,400 26% +1%

Newsprint 170,000 42,000 212,000 12% -2%

Packaging P & B 466,200 403,300 869,500 49% +3.5%

Tissue/Sanitaries 30,000 65,000e 95,000 5% +4%

Other Paper &Board 24,000 115,800 139,800 8% +2%

TOTALS 950,200 822,500 1,772,700* +2.3%

*with exports

MARKET DRIVERS OF GROWTH -PULP &PAPER INDUSTRY_____________________________________________

• Growth in Exports (Electronics, Fruits, Handicrafts, Garments, Furniture)

• Growing Local Consumption (Processed Food, Appliances, Consumer goods) due to population growth and rising purchasing power (OFW,Tourism,BPO and service sectors)

• Rise of Small &Med. enterprises, incl. provincial, agri- areas

• Growth in Education, literacy, cultural levels

• Growth in Entertainment, Sports, Fashion industries

• Expansion in domestic retail trade and inter-island commerce

(Packaging &documentation of goods moving frm provincial producers to consuming cities,towns)

SPECIFIC PROJECTS AND PROGRAMS RECOMMENDED_____________________________________________

• RAW MATERIAL (5-8 years)

– Estab. Mechanized wastepaper sorting plants in urban areas

– Develop industrial tree plantations of fast-growing species (5-years gestation) in logged-over and denuded areas

– Agro-Forestry/Tree farmer cooperatives for privately-owned lands

– Social Forestry for informal settlers and indigenous peoples

– Encourage contract-tree growing for wood-based industries (timber, biomass energy, paper pulp, chip exports).

– Invest in wood-based market pulp mill

• Proposed site : Northeastern Mindanao (Caraga, Reg.11)

FOREST-BASED PULPMILL PROJECT FOR PHILS._____________________________________________

• Proposed Capacity : 330,000 Tons/Year (1,000 Tons/day)

• Product Grades : Market Pulp (Hardwoods)

• Target Market : – 150,000 Tons/year Local demand (Bleached and Unbleached Pulps)

– 180,000 Tons/year Exports (Bleached Hardwood Pulp)

• Recommended Site : Eastern Mindanao

• Requires foreign equity investments to– help fund the Capital for the Project

– gain access to Export market

– acquire modern technologies in paper pulp manufacturing

• - Cont’d

FOREST-BASED PULPMILL PROJECT FOR PHILS. –p.2_____________________________________________

• Fast-growing species :– Mostly Acacia Mangium, Eucalyptus hybrid spp, Gmelina, etc.

• Reforestation / re-planting cycle : 5 – 7 years

• Areas to be developed into sustainable forests: – Industrial Tree Plantation : 20,000 hectares

– Agro- and Social Forestry : 30,000 hectares

SPECIFIC PROJECTS AND PROGRAMS RECOMMENDED_____________________________________________

• PRODUCT UPGRADES / IMPORTS REPLACEMENT (3-5 years)

– Invest in agri waste-based pulp mills (using rice straw, bagasse, corn stalk, palm oil /pineapple/tobacco wastes) – 50-100 Tons/day

• Proposed site : Northern/Central Luzon, Negros, Mindanao

– Invest in non-wood pulpmills utilizing annual plants (abaca, banana, kenaf, bamboo) – 30-50 Tons/Day

• Proposed site : Bicol, Southern Luzon, Leyte, or Mindanao.

– Invest in non-integrated kraftliner paper mill to serve the needs of fruit exporters and high-quality packaging requirements (300-500 Tons/day)

• Proposed site : General Santos, Davao or Cagayan de Oro

UPGRADE FPRDI-DOST R&D CAPABILITIES TO SUPPORT:

• Program to acquire new testing facilities for FPRDI Lab (Est. Budget P10 Million)

• Project to reactivate/replace the Pilot paper machine at Los Banos, as Center for research and training of industry personnel and engineering students.

• Program to strengthen the cooperation in Research and Lab. services at DOST-FPRDI with the pressing technical requirements of the Paper industry.

• Establish formal Training programs for Paper industry personnel and new Engineering graduates with both FPRDI-DOST and TESDA.

Jobs generation aspects of Pulp &Paper Mills

Employment/Livelihood generation = Direct Indirect

Integrated Pulp-Paper Mill, 500-TPD 1,300 30,000

Recycle-based Paper Mill, 300-TPD 250 87,500

Market Pulp Mill, 1,000 TPD 500 140,0008+20, 2.7+6

PAPER INDUSTRY ROADMAP – Goals and Programs_____________________________________________

• Short-Term (2014-2016):– Raise local paper recovery rates to 60%

– Discourage exports of local wastepaper

– Launch large-scale tree plantations for pulp,timber,biomass

– Plan and begin the engineering for a modern pulpmill project

– Upgrade technologies at existing mills

– Build local capabilities to produce higher grades of paper

– Establish smaller pulpmills for agri-wastes and annual crops

– Upgrade the research and training facilities of FPRDI.

• - Cont’d

PAPER INDUSTRY ROADMAP – Goals and Programs_____________________________________________

• Medium-Term (2017-2022):– Further raise paper recovery rates to 70%

– Construction and startup of wood pulpmill

– Upgrade/expand existing mills to produce Hi-grade paper

– Expand forest plantations to support pulpmill project

– Continue upgrading the production technologies of old mills

• Long-Term (2023-2030):– Expand production of non-wood pulp and paper

– Retire old machines and consolidate operations of small mills

– Expand Exports of pulp

• - Cont’d