Interview with Mr. Aejaz Ahmed Munshi, General Manager, Star Paper Mill, Abu Dhabi (ICAD), United Arab Emirates.
A new and modern hygiene tissue paper manufacturing mill spread over 27,000 sq m, is located in the growing Industrial City of Abu Dhabi (ICAD), United Arab Emirates.
Paper Desk : How much water is typically used in your paper mill’s production process, and how do you measure and monitor water usage across different stages of production?
Aejaz Ahmed Munshi : Our tissue mill with a capacity of 100 TPD, utilizes approximately 6-7.5 m³ of water per ton of paper produced. Water usage is closely monitored through digital flow meters installed at critical stages including raw water inlet, stock preparation, machine showers, white water recovery, and effluent discharge. This system enables real-time tracking and data logging to identify optimization opportunities.
PD : What technologies and strategies has your mill implemented to reduce water consumption effectively?
AAM : We have implemented a range of water-saving measures including efficient high-pressure showers and optimized dilution control in stock preparation. Additionally, we maintain a closed-loop system for fiber recovery and reuse process water extensively in the wet-end. Regular audits and operator training ensure sustained water efficiency.
” We aim to provide high-quality paper products that meet diverse needs while supporting our environmental goals “
PD : How does your mill approach water recycling, and what percentage of water is generally reused within your production process?
AAM : Water recycling is integral to our operation. We reuse approximately 75–80% of the process water, primarily through white water loops and backwater recovery systems. Recovered water is filtered and reused in applications like machine showers, vacuum seal water, and dilution circuits..
PD : What types of final water treatment processes does your mill use, and how do you ensure compliance with environmental standards?
AAM : Our Effluent Treatment Plant (ETP) includes primary clarification, aeration, and sludge dewatering systems. Continuous online monitoring of key parameters (pH, Conductivity, COD, DO, TSS) ensures that treated water meets all local environmental discharge norms. We maintain strict compliance with regulatory reporting requirements.
PD : How does your team maintain water quality throughout the production process, and what challenges do you face in doing so?
AAM : Water quality is managed through a combination of real-time sensor monitoring and regular lab analysis of process water, including parameters like conductivity, turbidity, pH, and microbial count. We use automated dosing systems to manage chemical balances, and water used in sensitive areas is filtered through multi-grade filtration units. The main challenge is maintaining consistency in incoming water quality, which is addressed through pre-treatment.
PD : What are the primary sources of water pollution in your mill’s papermaking process, and what measures are in place to mitigate these effects?
AAM : The major contributors to water pollution are suspended solids, fibers, and chemical residues from wet-end additives. To control this, we use fiber recovery systems such as save-alls and tiger floats, and all effluent is routed through a robust ETP. Sludge is managed via dewatering and disposal through authorized handlers.
PD : How do fluctuations in water availability, such as during droughts, impact your production process, and what contingency plans does your mill have in place?
AAM : Being located in the UAE, our water supply is sourced from municipal RO-treated seawater, which ensures consistent quality and availability throughout the year.
As such, we are not directly impacted by natural droughts or seasonal variations. However, we maintain adequate on-site storage to manage any short-term supply interruptions due to infrastructure maintenance or operational issues. Our process systems are designed for efficient water use, and production is planned with water reliability in mind.
PD : How does your mill handle wastewater, and what methods do you use to minimize its impact on local ecosystems?
AAM : All process wastewater is treated in our ETP before being discharged in compliance with environmental regulations. Treated water is routinely tested, and we strive to reuse a portion of the treated effluent for non-critical applications. We also conduct regular environmental impact assessments to ensure ecosystem safety and water neutrality targets.
PD : What role does regulation play in water management at your mill, and how do you adapt to changing regulations on water usage and discharge?
AAM : Regulatory compliance is central to our water management strategy. We align our practices with both national and local environmental laws and maintain proper documentation of discharge parameters and water consumption. Our internal compliance team ensures we adapt swiftly to any new requirements, including through upgrades in monitoring and treatment technologies.
PD : Could you share any recent innovations your mill has implemented in water management, and how have they affected sustainability and operational costs?
AAM : We have recently upgraded our water management systems with automated shower units fitted with variable frequency drives (VFDs), smart control valves and AI monitored back water control system. This has allowed us to precisely regulate water flow based on process needs, resulting in significant water savings and reduced energy consumption.
Additionally, we installed a high-efficiency fiber recovery system to reclaim usable fiber and improve white water clarity. These initiatives have contributed to improved sustainability metrics, reduced ETP load, and notable cost reductions in both water and energy usage.