JCM_ID_F_PDD_ver01.1

JCM Project Design Document Form
A. Project description
A.1. Title of the JCM project
Reduction of Energy Consumption by Introducing an Energy-Efficient Waste Paper Processing
System into a Packaging Paper Factory in Bekasi, West Java
A.2. General description of project and applied technologies and/or measures
The demand of paper has grown rapidly in Indonesia driven by its high economic growth. As
one of the leading companies of corrugated carton production in Indonesia, PT FAJAR SURYAWISESA (Fajar Paper) decided to equip higher energy efficient technologies of Aikawa Iron
Works than those for existing Line 5 in its newly built production Line 8 as a JCM project.
A corrugated carton production process consists of the following two main processes: oldcorrugated cartons (OCC) process and sheet forming process. This project aims to reduce electric
power use in the former process.
Whole Processes of Production of Cardboard
OCC Line.
C C E/ C E.

C C E F

FFB I
EFunction

Manner ofCO2reduction

A E

PM Line

B EF
1 E A

BI A /EBC E FEA
1 E A

E C EFF
BE /EB FFBEBI A
E BI AC E FC E F

E AA FC
E I
A E/ EFBA
A 1 E A FF/ C E BAF F F B
DEB BE B E
E AF E A E EB BEEBBA FC
BE EA FCAEC E F ABA E
E I
FB B E
2 BF C E F AB
CB E
B FAM
AE BBA E
E F EBAAA E
C F
C E FB B
A/ C E , BA E
F BE
A B 1 E A
CEB FF B B EB
B 1 E A

Figure 1:/E FF C E/ C F AF C C EI A BA EFE AFA
C C EBE
E F BEFE A
C C F EE A/BC EE C E

E B
B BAAEERewinder

C C E/ C EEEA FF
B C C E E
F E-AF

OCC process in the entire cardboard production processes

In the OCC process, the material of sheet paper is made by removing foreign substances, using
multiple machines from ground and then liquefied old paper with water. This process iscomposed of 4 components based 30 equipment. It is expected the specific energy consumptionof the project OCC Line 8 is around 0.12 MWh/ton (for 1,400 ton/day), in comparison to thehistorical performance of the existing OCC Line 5 (0.188 MWh/ton) whose output product isthe same of the Line 8.

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A.3. Location of project, including coordinates
CountryIndonesia

Region/State/Province etc.:

Jawa Barat/ Bekasi

City/Town/Community etc:

Cikarang Bar/ Kalijaya/ Jl. Kampung Gardu Sawah No. 1

Latitude, longitude

16°16'20"S107°07'22"EA.4. Name of project participants
TheRepublic

Indonesia
JapanofPT FAJAR SURYA WISESA Tbk.
KANEMATSU CORPORATION

A.5. Duration
Starting date of project operation

1 April 2017

Expected operational lifetime of project

12 years

A.6. Contribution from Japan
The proposed project was partially supported by the Ministry of the Environment, Japan (MOEJ)
through the Financing Programme for JCM Model projects, which provided financial support ofless than half of the initial investment for the projects in order to acquire JCM credits. The
Japanese project participant transfers the technology through conducting the training on
operation and maintenance of newly installed equipment through this project.

B. Application of an approved methodology(ies)B.1. Selection of methodology(ies)
Selected approved methodology No.

ID_AM012

Version number

1.0

B.2. Explanation of how the project meets eligibility criteria of the approved methodology
Eligibility

Descriptions specified in thecriteria

methodology

Criterion 1

The specific energy consumptionof the project OCC line guaranteedby the manufacture is, at the2Project information
Project specific energy consumption(0.120 MWh/ton for 1,400 ton/day) forLine 8 expected by Aikawa Iron Works isless than historical performance of Line 5(0.188 MWh/ton) which produces

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minimum, less than the reference
specific energy consumption set forequivalent product.
[Note: ton implies BDt (Bone Dry ton)]

the project factory.
Criterion 2

The paper yield of the project OCCline(s) guaranteed by themanufacture is equal to or morethan 90% at the range of designed

The guaranteed paper yield is 92% in theproject OCC line 8 as shown in “6.4.4.2.
Fiber Loss Amount” of the “Technicalguarantees” provided by Aikawa IronWorks,production capacity.
Criterion 3

Production capacity of the project
OCC line is no more than the twiceas large as the capacity of theexisting OCC line

Criterion 4

Plan for regular adjustment,replacement, and improvements ofproject OCC line(s) are prepared(at least once every six months).

Project capacity of the OCC Line (1,400ton/day) is less than the twice as large as
1,150 ton/day, which is the maximum
capacity of existing OCC line 5 which
produces equivalent product.
Aikawa Iron Works agreed with Fajar togive the appropriate advices for the stable
operation of the Line 8 every 3 months
with the visit at least every 6 months(Agreement signed on August 28, 2015).

C. Calculation of emission reductions
C.1. All emission sources and their associated greenhouse gases relevant to the JCM projectReference emissions
Emission sources

GHG type

Electricity consumption by the reference OCC line(s)CO2Project emissions
Emission sources

GHG type

Electricity consumption by the project OCC line(s)CO2C.2. Figure of all emission sources and monitoring points relevant to the JCM project
Monitoring Points in Whole Process
For monitoring, Fajar uses energy management system “DCS” and reporting system “SAP”.
At this factory, Line 8 has its energy monitoring/control room. It collects and records monitored
electricity consumption of each facility of the OCC line every hour.
Fajar monitors electricity consumption and paper production weight. For electricity, data ofPulper, Coarse Screen and Fine Screen are only measured.

Paper production weight ismeasured by weight bridge at the last process. Both electricity and paper production (Gross) are3

JCM_ID_F_PDD_ver01.1

automatically monitored.
DCS

Monitoring points

OCC electricity

Warehouse system(SAP)

PM electricity

Paper Production

Monitoring data２

１

O ld
p a p er

Pu lp er

C lea n er

PM LineC o a rse
S creenF in eS creen

W ire p a rt

Press p a rt D ry p a rt

BM /Po p e reel

RewinderWeight bridge

OCC Line

M ed iu mp a p er

Figure 2: Schematic chart of monitoring system
C.3. Estimated emissions reductions in each year
Year

Estimated Reference

Estimated Project

Estimated Emission

emissions (tCO2e)

Emissions (tCO2e)

Reductions (tCO2e)

201739,433.5

25,174.8

14,258

2018

52,578.0

33,566.4

19,011

2019

52,578.0

33,566.4

19,011

2020

52,578.0

33,566.4

19,011

Total (tCO2e)

197,167.5

125,874.0

71,291[Note] The emission reductions are counted from April 1, 2017.
D. Environmental impact assessment
Legal requirement of environmental YES.
impact assessment for the proposed

In addition to the EIA (UKL-UPL) obtained in 2015

project(660.2.1/084/TL&ADL/BPLH), Fajar owns theEnvironmental Permit (Nomor: 503.9.a/Kep 127/
BPMPPT/V/2015). EIA (UKL-UPL) is governed by
the Indonesian Law Number 32 (2009). While theEnvironmental Permit is governed by Government
Regulation Number 27 (2012). Both the Permit andEIA complement each other.

E. Local stakeholder consultation
E.1. Solicitation of comments from local stakeholders
Local Stakeholder Consultation (LSC) had been held in 20th December, 2016, which had invited
several stakeholder; Staff of Fajar Paper, Indonesian Government and Indonesian Pulp and Paper

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Association.
Date/Location
Date: 20 December, 2016
Venue: Mill site of PT FAJAR SURYA WISESA Tbk.
LSC Agenda
10:00~10:15: Time adjustment
10:15~10:20: Opening remarks by Mr. Roy of Fajar
10:20~10:30: Introduction of relative entities
10:30~10:50: JCM introduction by Yoshimoto of NRI
10:50~11:00: JCM in Indonesia by Ms. Keni of JCM secretariat
11:00~11:20: Introduction of Fajar and Line 8 by Mr. Hardy of Fajar
11:20~11:40: JCM boundary and Equipment of JCM project by Mr. Aoshima of Aikawa IronWorks
11:40~11:45: Q&A
11:45~11:50: Closing by Mr. Asami of Kanematsu
12:00~13:00: Lunch organized by Fajar
13:00~14:00: Mill site tour organized by Fajar
List of Participants,Organization
FajarPaperKanematsu
Aikawa Iron Works
Nomura Research Institute
SUNCOSMO
JCM secretariat
Coordinating Ministry of Economic Affairs
Ministry of Industry
APKI(Indonesian Pulp and Paper Association)
E.2. Summary of comments received and their consideration
StakeholdersComments received

Consideration ofcomments received

Director of Fajar

Japanese stakeholders involved into this project
5No Action

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Paperis appreciated and the enthusiasm for utilizingand further promoting JCM is mentioned.

Indonesia JCM

This project is positioned as a first project ofsecretariat

paper industry in Indonesia and an important

No Action

project. Moreover, in order to develop theproject horizontally to other paper factories inIndonesia, it is pointed to set up committees
involving public and private sectors in the paperindustry and to appeal the results of this JCM
project.
the Ministry ofAn introduction about the efforts of the paper

Industryindustry in the Ministry of Industry is given.

No Action

The energy reduction amount by the project
OCC was asked.
Indonesian pulp andThe total production capacity and yield of LINE

paper Association

8 was asked.

F. References– UKL-UPL report (660.2.1/084/TL&ADL/BPLH)–

Environmental permit (Nomor: 503.9.a/Kep 127/ BPMPPT/V/2015)

Reference lists to support descriptions in the PDD, if any.
Annex–Revision history of PDD
VersionDate

Contents revised

0.1

13/02/2017

Initial draft.

1.0

18/09/2017

Revised for validation.

1.1

22/09/2017

Revised for validation

1.2

27/11/2017

Revision with revised emission factors

6No Action