Pulp-paperworld magazine issue 5

PULP-PAPERWORLD Latest News from www.pulp-paperworld.com

Issue no. 5 August 2011

Simpele board mill Rebuild completed ITC India Orders Two Sheeters from MarquipWardUnited ABB Wins Electrification Order for Pulp Mill in Uruguay

Contents

Issue No. 5 Melin-Jones Media Visiting Address: Hjulsta Backar 25 163 65 Spånga Stockholm Sweden Phone: +46 (0) 8 120 932 01 Mobile: +46 (0) 72 25 33488 www.pulp-paperworld.com Publisher Ian Melin-Jones Owner of Pulp-paperworld.com Tel: +46 (0) 8 120 932 01 info@pulp-paperworld.com Advertising: Ian Melin-Jones Tel: +46 (0) 8 120 932 01 marketing@pulp-paperworld.com Contributors: Mika Joukio Eamon Devlin Trish Kempkes Eva Soderberg Ulrich Höke Hosting Issue.com

Page 4 Simpele board mill Rebuild Completed

Page 7 ABB Wins Electrification Order for Pulp Mill in Uruguay Page 9 Upgrade your blades and protect your Yankee Page 14

Metso Paper pleased with collaboration

Page 16 ITC India Orders Two Sheeters from MarquipWardUnited Page 20 ABB to supply automation and

electrification for new bioboiler at Bomhus Energi Page 24

European Declaration on Paper Recycling 2006 – 2010

FiberScan

™

NON-RADIOACTIVE

The new microwave instrument to analyse the drainage of forming fabrics.

No more formalities, travelling is now as easy as A, B, C! www.feltest.com 2007236 Feltest advertenties.ind1 1 Proceskleur CyaanProceskleur MagentaProceskleur GeelProceskleur Zwart

10-08-2007 11:01:03

Simpele board mill

Rebuild completed

By Mika Joukio, Senior Vice President, Head of M-real Consumer Packaging

MORE FOLDING BOXBOARD FOR FOOD INDUSTRY TO MEET DEMAND

M-real completes improvements at Simpele Mill increasing capacity by 80,000 tpa An additional 80,000 tonnes per annum of folding boxboard, primarily aimed at meeting increased demand from the food industry, is coming on stream following completion of a rebuild at M-real’s Simpele mill in Finland. The rebuild was finished according to schedule on June 1st 2011.

Photo : M-real

In addition to Simpele, M-real is increasing capacity at its Äänekoski and Kyro mills, planned for completion in late 2011 and spring 2012 respectively. As a result of the rebuilds, M-real will increase its total folding boxboard capacity to around 935,000 tonnes and further strengthen its position in the market. M-real is also investing at its Kemiart Liners mill and in the construction of a bio power plant at Kyro. In total, investment in the Consumer Packaging business

area will exceed EUR 100 million during 2010-2012, Simpele being the first phase of the investment programme.

“Demand for our primary fibre boards has been excellent, due not only to their high performance and sustainability, but also due to rising concern over product safety,” says Mika Joukio, Senior Vice President, Head of Consumer Packaging for M-real. “We can now fulfill more orders for Simcote, a pure and lightweight grade ideal for food

packaging, as well as other end uses such as pharmaceuticals where safety is paramount.”

M-real Simpele is already considered the most efficient cartonboard mill in Europe and Simcote the most efficient board grade as defined by its consistency and yield. The EUR 26 million invested at Simpele will increase production capacity by 80,000 to 300,000 tpa and sheeting capacity by 40,000 to 230,000 tpa.

Simpele, board machine

M-real in brief: M-real is Europe’s leading primary fibre paperboard producer and a major paper supplier. The company’s customers include brand owners, carton printers, converters, publishers, printing houses, merchants and office suppliers.

M-real supports its customers’ businesses by providing high-performance paperboards and quality papers for consumer packaging, communications and advertising end-uses.

Together with its customers and partners, M-real develops products and services for demanding end uses. The company’s paperboard is mainly used for the packaging of beautycare and healthcare products, foods, cigarettes, and consumer durables as well as graphics. Paper is mainly used for office papers as well as wallcoverings and other speciality end uses.

M-real’s business areas are Consumer Packaging, Office Papers, Speciality Papers and Market Pulp and Energy.

M-real Simpele, reeler

ENVIROMENTALLY FRIENDLY

stickies control , deinking , and production enhancement technology for papermills worldwide

SELLING IN THE WORLD MARKETS ENESSCO INTERNATIONAL has been selling commercially in the paper industry worldwide for over 18 years. During this time the company has accumulated a substantial body of evidence to support its many and varied claims on the performance of its products. Our technology is now in use in many of the worlds leading Tissue and Board mills and any mill using recycled fiber or dinked pulp.

Products on offer ENESSCO D 2000 - Advanced Deinking Technology ENESSCO S 1000 - Production Enhancement Technology ENESSCO INT. ENHANCED - Contaminte Control Technology NOW RUNNING IN BROWN, TISSUE & DEINKED MILLS AROUND THE WORLD! ELIMINATE THE HIGH COST OF WAX, STICKIES AND CONTAMINATES PROBLEMS OR IF YOU ARE A TISSUE MILL THEN - NO MORE SOLVENTS, A SOFTER SHEET AND UP TO A 3 POINT INCREASE IN BRIGHTNESS !!!!!

750 Exeter Road, Hampton, NH 03842 USA | (603) 926 4830 | Fax (603) 926 0445

FOR MORE INFO PLEASE CONTACT: steve@enessco.com

ABB Wins Electrification Order for Pulp Mill in Uruguay

The Montes del Plata pulp mill

ABB, the leading power and automation technology group, has won an order to supply process electrification and power distribution infrastructure as well as equipment for a new pulp mill in southwestern Uruguay.

The Montes del Plata pulp mill is a joint project of Finnish pulp and paper manufacturer, Stora Enso, and the Chilean forestry company, Arauco. At an estimated cost of $1.9 billion, it is the largest private investment ever made in Uruguay..

The mill is scheduled to be begin production in the first quarter of 2013, and will have an annual capacity of 1.3 million metric tons of bleached eucalyptus kraft pulp sourced from Montes del Plata’s own forestry plantations.

The project includes the pulp mill, a deepwater port and a biomass-based power generation plant to convert waste from pulp production into electricity.

“ABB has delivered and managed large, complex electrification projects for the pulp and paper industry for more than 40 years,” said Veli-Matti Reinikkala, head of ABB’s Process Automation division. “Our advanced technology can also help customers efficiently tap into local renewable energy sources, ensuring this stateof-the-art mill has a reliable, self-sufficient electrical supply.”

ABB will provide power distribution and process electrification for the pulp mill, including the main transformers, 33 kilovolt (kV) power distribution system and control system, smart motor control switchgear, all motors and frequency converters. ABB will also deliver the sectional drive systems for the two pulp dryer machines, including hardware and software engineering, as well as on-site services for customer training, start-up and commissioning.

ABB’s Process Automation division delivers industry specific solutions and services for industrial automation and plant electrification. These solutions help customers meet their critical business needs in the areas of energy efficiency, operational profitability, capital productivity, risk management and global responsibility. Available industry specific solutions include process control, instrumentation, analytics, safety, plant optimization, telecommunications, energy management and power distribution.

ABB (www.abb.com) is a leader in power and automation technologies that enable utility and industry customers to improve their performance while lowering environmental impact. The ABB Group of companies operates in around 100 countries and employs about 124,000 people.

To analyze the performance of each blade type, we measured roughness (Ra) value, Yankee wear-incurred weight loss, and temperature induced at the blade tip.

Results from running the Yankee dry, without coating (a worst case scenario), revealed a dramatic contrast. The steel blade induced more than 15 times the weight loss caused by its ceramic counterparts, with blade roughness increasing by 78%.

Bad vibrations

Typical chatter marks. source BTG

Upgrade your blades and protect your Yankee Tests show that high-performance blades don't just last longer and save on downtime, they also result in much less wear and tear on the Yankee surface, protecting your cylinder and reducing the need for costly regrinding.

Soaring demand for an ever-wider range of tissue products is pushing papermaking technology to the limit, with new tissue machines, higher speeds, and a strong emphasis on improved quality and enhanced efficiency.

But today’s complex processes involving new chemistries, mechanical equipment, higher temperatures, lower moistures, and different fiber combinations can increase blade wear and the risk of damage to the Yankee cylinder. Whereas the mechanisms for frictional Yankee wear are now well understood, even with today’s sophisticated machine control systems, the phenomena responsible for blade chatter remain obscure, and require a multi-disciplinary approach and in-depth understanding of the complete tissue process to be successfully resolved.

Since their introduction back in the 1980s, high-performance long-life blades* have been making rapid inroads into the traditional steel blade market. But despite the tremendous productivity benefits these blades offer, some tissue makers remain hesitant to make the change. They question the impact of ceramic and cermet** materials on their cast iron or metallized Yankee, and are concerned about Yankee life and the cost of refurbishing the cylinder surface if damaged by chatter marks.

At BTG, we decided to combine our extensive troubleshooting experience, in-house research capabilities and holistic approach to tissue making to launch a series of projects aimed at better understanding the physical interactions between the creping blade and Yankee surface. To begin, we investigated the friction phenomenon and sources of chatter on tissue machines.

The impact of wear The definition of wear is a progressive loss or displacement of material from the operating surface of a body, occurring as a result of relative motion at the surface.

Wear induces damage resulting from loss of material (the ‘typical’ wear effect), but can also induce porosity damage caused by a transitory gain of material - for instance, with transfer of blade material onto the Yankee surface, and then the subsequent removal of this material in a destructive action (the primary failure mode for metallized surfaces).

To measure the effects of wear during the tissue production process, our engineers performed a comprehensive series of friction tests using creping blades made of different materials; steel, cermet (chromium carbide) and ceramic.

The primary cause of Yankee wear and damage is direct metal-to-metal contact between the cylinder and the steel doctor blades. However, experience shows that many other process situations induce vibrations that can result in chatter marks on the Yankee cylinder surface. Chronic damage can necessitate regrinding of the Yankee surface - an unwelcome expense that also entails considerable machine downtime.

While the use of cylinder coating mixtures offers a degree of protection from wear, ceramic blades represent a more positive and cost-effective long-term solution. Combined with suitable process conditions, these blades - unlike steel blades - ensure virtually no wear on the metallized Yankee surface from frictional interaction.

The real challenge lies in controlling the process so that vibrations remain low. This requires a structured approach and proven experience in chatter problem diagnosis and problem-solving.

BTG offers unrivalled expertise and competence when it comes to highperformance blades and an in-depth understanding of the paper-making process.

Our engineers are trained to take a holistic approach, considering each customer’s production parameters, constraints and desired results, and recommending the very best choice of blade material to meet their needs.

We commit ourselves to ensuring that every BTG recommendation results in reduced variability of tissue properties over time, higher blade lifetimes, and clear benefits ranging from the Yankee to the finishing room and, ultimately, the consumer. * ‘High-performance’ blades is a concept encompassing a range of specially-designed creping doctors, comprising a tailor-made working edge and different, applicationspecific tip materials and geometries. ** Cermet = ceramic/metal compound

The results confirm that ceramic and carbide blades significantly reduce wear on machine components and eliminate the potential for damage to the Yankee cylinder associated with steel blades.

EUROPEAN PAPER WEEK 2011

15–17 NOVEMBER 2011 BRUSSELS, BELGIUM

Organised by

Supporting

MORE INFORMATION AT

WWW.CEPI.ORG/EPW

Kindly sponsored by

Is ABB committed to pulp and paper?

Absolutely.

Maximizing the performance of your mill by adding cutting edge technology or simply fixing what’s broken is what you should expect from your automation and electrification partner. As an industry pioneer and leader in pulp and paper, ABB will always meet or exceed your expectations regardless of the age or history of your system. We did it yesterday and we will do it tomorrow. That is our pledge. www.abb.com/pulpandpaper

DHL Rail

DHL RAIL

GREEN LOGISTICS WITH DHL RAIL

DHL Rail is devising a green logistics structure to enable you and your company to achieve your environmental objectives and targets. Together we clarify your transport sustainability by measuring its impact on the environment. Therefore let DHL Rail help you and your company with what we excel at, sustainable logistics by rail, leaving you free to pursue your main business activities instead.

DHL Rail

ENVIRONMENTALLY PLANNED TRANSPORT DHL offers a total logistics structure in which the greater part of the transport is by rail. We look into your company’s requirements for sustainable transport and develop tailored solutions that help you and your company fulfil your environmental objectives. Naturally the results of the environmental impact of our transport together with your environmental objectives are measurable. For each transport time we submit an environment calculation, that corresponds to the reduced amount of energy consumption and carbon dioxide emissions that occurs when you choose DHL.

Pan-European presence incl. CIS countries

QUALITY AND SERVICES • • • •

•

• •

•

•

•

•

Logistics structure based on rail.

High quality and reliability.

Collection/ distribution, terminal handling/ warehousing.

Environment calculation, both before and after the transport.

Different types of loading units for both intermodal transport and conventional rail solutions, terminals and networks which provide both you and us with the flexibility and opportunity to also fulfil your customers’ requirements.

We secure the capacity of your transport requirements.

Long experience and expert know-how of sustainable logistics.

Monitoring and planning of your deliveries and the opportunity for well-proven and well-functioning structure.

Pan-European presence incl. CIS countries, which provides the requisite range.

A contingency plan for transport disruptions to guarantee your transport to the utmost possible extent.

Bulk transport and other special transport in which specific safety procedures are incorporated.

Contact us at DHL Rail

For more information and price enquiries, please contact us: Telephone: 0046-410-740 600 E-mail: contactrail@dhl.com

Metso Paper pleased with collaboration Metso Paper in Sundsvall manufactures, amongst other things, roller presses for the pulp industry. Avesta Welding has long been supplying the company's workshops with filler metals.

"In principle, we buy all our welding consumables from Avesta Welding. Our experience of this has always been positive," states Bjorn Jansson, production technician and IWS at Metso Paper in Sundsvall.

Metso is a global technology group that manufactures equipment for customers in, for example, the construction sector, power production, recycling and, not least of all, the pulp and paper industry. Metso Paper in Sundsvall manufactures machines and develops processes for the chemical and mechanical production of pulp and board. Bjorn Jansson relates that roller presses, screw conveyors and pressure vessels are some of the company's products.

"Twin roller presses that wash and bleach pulp are our main product. We supply them to customers all over the world. In the wash presses, most of the welding is duplex steel. For the rollers themselves, there is a lot of MIG and submerged arc welding. It's mainly manual metal arc and MIG for other components. The same applies to the

welding of pressure vessels, another of our major products," he says.

Fifty welders

Some 100 people, 25 of these being welders, are employed at Metso Paper's production unit in Sundsvall. Extra people are taken on to

handle high workloads. At present, there are an extra 25 welders.

Besides heavy and complex equipment, the workshops also specialise in welding. They are certified to carry out the welding of mild steel, austenitic steel, all duplex steels and titanium, etc.

Metso Paper's twin roller presses go to customers all around the world.

ITC India

Orders Two Sheeters from

MarquipWardUnited

ITC is one of India’s foremost private sector companies with a market capitalization of more than $30 billion and a turnover of $6 billion. ITC is rated among the World’s Best Big Companies, Asia’s “Fab 50” and the World’s Most Reputable Companies by Forbes magazine.

by Trish Kempkes Director of Global Communications

I

TC’s Paperboard and Specialty Paper Division (PSPD) operates India’s largest integrated pulping and paperboard manufacturing unit in Bhadrachalam, with a total manufacturing capacity of more than 350,000 tons of papers and paperboards per annum. ITC-PSPD is currently executing a capacity expansion project of 100,000 TPA. After extensive market research and fact-finding visits to many sheeting facilities for this project, ITC-PSPD chose MarquipWardUnited as its preferred sheeting technology partner. MarquipWardUnited is a division of Barry-Wehmiller Companies, Inc., a $1 billion global provider of manufacturing equipment solutions and the largest packaging machinery group in the Western Hemisphere.

It was decided that a partnership between the two companies would provide ITC with the sheeters needed to improve both performance and quality. Both ITC and MarquipWardUnited see this order as the first step in a long and mutually beneficial relationship.

Two MarquipWardUnited SheetWizard sheeters equipped to produce dust-free, press-ready sheets running with one or two reels were specified to meet the exact needs of ITC and to accommodate the growing quality demands of India printers and folding carton manufacturers. With more modern high-speed presses being installed in India, only sheets cut to the tightest tolerances will allow the printer to reach the maximum output potential.

“We have been trying for some time to enter the Indian paper and board mill

Pictured (from left): Michael Gennis, MarquipWardUnited; Rakesh Gupta, ITC General Manager – Projects; and Steve Brimble, MarquipWardUnited

market,” explained MarquipWardUnited area sales manager Michael Gennis. “In ITC, we have found a superior partner for this first success.”

Rakesh Gupta, ITC General Manager – Projects, commented, “From the unique MarquipWardUnited technology, we are expecting a high output as well as excellent cutting quality and cutting accuracy, combined with a reduced power consumption of 50 percent compared to sheeters from other suppliers.”

For more information about the complete line of sheeting systems from MarquipWardUnited, please visit www.marquipwardunited.com or contact Steve Brimble on +1 44 1761 453 889 or steve.brimble@marquipwardunited.com.

Pulp-paperworld 5/2011 3

Improve your bottom line!

Your daily production problems are our challenge - get expert advice and tailor-made complete solutions from BTG.

Talk to the experts! www.btg.com

info@btg.com

Web Business Directory

To B or not 2B That is the Question!!

Did you know Pulp-paperworld.com’s B2B directory reaches over 75 countries?

For just

350€ you can also be seen.

• Unlimited text • Unlimited Graphics • Logo type • Contact Details • No yearly renewal fees • Up to 5 Catagories, we can make one for you if needed.

Don’t wait Click Here to Order

Pulp-paperworld.com | Tel +46 8 120 93201 | marketing@pulp-paperworld.com

ABB to supply automation and electrification for new bioboiler at Bomhus Energi in Gävle, Sweden ABB’s automation and electrification systems help create an environmentally friendly, reliable and efficient operation

ABB, the leading power and automation group, has won an order for the electrification and automation system of a new bioboiler and turbine, including fuel management, from Bomhus Energi in Gävle, Sweden.

Bomhus Energi AB, a joint venture of Gävle Energi AB and Korsnäs AB, will supply steam and electricity to the Korsnäs plant in Gävle as well as district heating to the Gävle town district, with the new bioboiler.

“The new boiler will replace an older boiler at Korsnäs, and will be both more environmentally friendly and more efficient,” says Mats Törnkvist, technical manager at Korsnäs and Bomhus Energi AB board member.

The ABB supply scope includes low-voltage switchgears for energy-efficient motor control and monitoring of more than 400 motors, 18 energy-efficient and environmentally friendly Resibloc transformers and shunt ca-

pacitors to improve power quality. Bomhus has also ordered an ABB Automation System 800xA for controlling and monitoring the boiler.

“The automation system will control and monitor a complex process with high safety requirements. The boiler, the fuel management, a new turbine and the integration of adjacent process sections must be monitored and 100% controlled, a function that now will be significantly simplified with the new automation system,” says Törnkvist.

In addition to advanced control and monitoring functions, the automation system includes new operator stations, integration of switchgear and motor operations and an environmental report system, as well as realtime monitoring of every instrument circuit. System 800xA will be based on virtual servers, saving space and considerably

simplifying system testing and future upgrades.

To create a new joint operator environment, older operator stations will be replaced with new 800xA units for adjacent process sections. The project includes all system work, programming, test runs and commissioning.

The new boiler will be fully operational by fall 2012.

ABB (www.abb.com) is a leader in power and automation technologies that enable utility and industry customers to improve performance while lowering environmental impact. The ABB Group of companies operates in around 100 countries and employs about 124,000 people.

For more information please contact: Eamon Devlin Global Marketing & Communications Manager QCS & WIS Tel: +353 42 938 5103 eamon.devlin@ie.abb.com

ADDING VALUE TO PAPER

ADDING VALUE TO PAPER – JUNE 2010

IMPACT

GLOBAL

design: sheardhudson.com

For and about people at Pigments for Paper

FOR AND ABOUT PEOPLE AT PIGMENTS FOR PAPER Europe Tel: +358 20 757 7700

Asia Pacific Tel: +65 67 99 60 60

N. America Tel: +1 770 594 0660

S. America Tel: +55 11 2133 0055

Internet: www.imerys-paper.com

Get the Edge Over Your Competition “Exclusive Patented Products for the Pulp & Paper Industry�

Current Model Hydro-Flo Systems feature an all new seal design which is up to 40% more efficient than even last years models. Combine this with our unique all stainless steel Quick-Release & Pivoting mounting hardware for our finest Edge Control System, ever!

Every Hydro-Flo System is offered with installation and approval drawings.

Hydro-Flo Systems require little, if any, inside engineering.

PSI specializes in providing turn-key systems with very fast ROI. Let us know how we can help you maximize your processes!

The Hydro-Flo System is very low maintenance and totally adjustable in all directions.

Best of all, this system performs on all weights, speeds and grades, regardless of product.

Hydro-Flo Deckles are the #1 selling, patented, wet-end Edge Control System, worldwide!

Papermachine Service Industries was founded in 1976 to produce the finest slotted ceramic vacuum box covers and foils ever. In 1980, we started producing Edge Control Systems and shortly after that introduced the first models of the Hydro-Flo Deckle Systems. Since then PSI has been innovating edge control systems, with our finest systems offered this year with the current model Hydro-Flo Systems.

Our work and expertise on the wet-end of the paper machine, from dewatering elements and equipment, to edge control technology and fiber alignment and formation specialty products, PSI is your source for innovative and unique systems to improve your paper product and your bottom line!

Papermachine Service Industries, 3075 Shattuck Suite 801, Saginaw, Michigan 48603, USA Direct: +1(989)695-2646 - Fax: +1(989)695-2648 - psisales@papermachine.com

www.papermachine.com

European Declaration on Paper Recycling 2006 – 2010 Monitoring Report 2010

Contents Five Years of Raising the Bar in Paper Recycling Recycling Rate 2010 Data Quality Progress in Qualitative Targets 2006 – 2010 Growing Stronger as a Value Chain Glossary Assurance Report 2010 by PwC European Recovered Paper Council

Five Years of Raising the Bar in Paper Recycling This is the final report for the commitment period of the 2nd European Paper Recycling Declaration 2006-2010.

Since 2004 the recycling rate has increased by 10% points due in part to the excellent work of the European Recovered Paper Council (ERPC).

The economic recession which started in late 2008 continued in 2009 and 2010. As with any other statistics, those years should not be considered representative for the European paper recycling rate. Although paper consumption in 2010 was not as low as the year before (equal to consumption level of 1997), it was still much lower than before the economic recession started. As the recycling rate is the ratio between the recycling and the consumption of paper, the abnormal fall in consumption – whereas the recycling continued at high levels – resulted in unexpectedly high recycling rates both in 2009 and 2010.

This effect will even out in the coming months and years and the paper value chain will return to the normal trend.

As the 2010 Monitoring Report is being published, a new ambitious commitment for 2011-2015 is being prepared, keeping the industry on its path to meet ambitious targets of recycling paper at a steadily increasing rate in Europe.

For the commitment period of 2006 to 2010, PricewaterhouseCoopers has independently verified the calculation of the recycling rate using the International Standard on Assurance Engagements ISAE 3000 (see report on page 7).

In addition to the quantitative progress, a lot of qualitative work was done to establish an eco-design towards improved recyclability and in the area of waste prevention. You can read more on pages 4 and 5, including a concise summary of the past 5-year period. The past five years gave the ERPC an opportunity to learn how to work better together, growing stronger as a value chain.

Brussels, 27 June 2011 The 2010 European paper recycling rate of 68.9% is higher than the target set by the ERPC, and the group is proud to report on impressive work completed to reach it, following the commitment it first made in 2000 to increase paper recycling in Europe.

Monitoring Report 2010

Ulrich Höke Jori Ringman Chairman Secretary

2

Recycling Rate 2010 The recycling rate in Europe reached 68.9%1 in 2010. The total amount of paper collected and sent to be recycled in paper mills came to 58 million tonnes, the same as the previous year, but an increase of 5.8 million tonnes since 2004, the base year for the current target the industry has set itself for increasing recycling in Europe.

A net volume of 8.4 million tonnes (or 15%) of the total 58 million tonnes was exported for recycling in third countries outside the commitment region of EU-27 plus Norway and Switzerland.

European Paper Recycling 1995-2010 Million Tonnes

100 80 60 46.6%

49.2%

49.2%

1995

1996

1997

50.2%

52.2%

51.8%

54.7%

55.8%

56.6%

59.0%

62.1%

63.1%

64.6%

66.7%

2006

2007

2008

72.3%

68.9%

40 20 0 -10

Recycling outside Europe

1998

1999

Recycling in Europe

2000

2001

2002

2003

Paper & Board Consumption

2004

2005

2009

2010

Recycling Rate

Data Quality 2011 (2010 Data) The data used to calculate the recycling rate is collected by CEPI (Confederation of European Paper Industries). The data comes from the results of a questionnaire sent by CEPI to its national member associations (Austria, Belgium, Czech Republic, Finland, France, Germany, Hungary, Italy, the Netherlands, Norway, Poland, Portugal, Romania, Slovak Republic, Slovenia2, Spain, Sweden, Switzerland and the United Kingdom). The national associations supply the data, which they collect from their member mills/ companies plus official sources where appropriate.

The data, including recovered paper utilisation and trade plus paper and board production, trade and consumption for non-CEPI members of the EU-27 (Bulgaria, Cyprus, Denmark, Estonia, Greece, Ireland, Latvia, Lithuania, Luxembourg and Malta) is obtained from PĂśyry Consulting.

After being submitted to CEPI, the data may be adjusted, in particular the trade data obtained from customs. The figures will be considered final as published in the subsequent report (e.g. 2009 figures in this report). The 2009 recycling rate is confirmed at 72.3% (instead of 72.2%).

For certain countries3, where the calculation of the mass of recycled paper and board based on recovered paper utilisation and net trade has not produced a result which is considered to be an adequate reflection of reality, recycling has been based on actual paper and board collection for the specific purpose of recycling. This alternative methodology is mainly called for by the relatively high trade volumes in the Netherlands, which complicates the exercise of distinguishing domestic utilisation from trade of recovered paper.

It should be noted that this change has a reductive impact on the overall recycling rate as the usual calculation method would over estimate actual recycling in the Netherlands. Other countries4 have adjusted consumption figures with the opposite impact.

All historical annual recycling rates have been recomputed based on the revised calculation methodology.

1 2

See Assurance Report 2010 by PwC on page 7.

Slovenia joined CEPI in 2010. Data applied by the association has been used for 2010 and previous years’ statistics, which may have been revised.

Monitoring Report 2010

3 4

Finland, France, the Netherlands and Sweden.

Finland, France, Germany, the Netherlands, UK.

3

Progress in Qualitative Targets By joining the European Declaration on Paper Recycling, European Recovered Paper Council (ERPC) members committed themselves to carrying out qualitative actions, in particular by using the eco-design of paper products, to improve the recycling rate by 2010. The members represent 14 sectors along the paper value chain. In 2010, as in the previous 4 years, ERPC members dedicated a substantial amount of their time to several initiatives that will facilitate the recycling process and increase recycling activity.

Collection ERPA members have, through their national associations, organised meetings with various industry partners and, in some countries such as Hungary, competent authorities in order to improve collection systems and develop incentive programmes.

Additional sorting lines, machines and equipment were invested in and quality management systems were developed in many companies to produce higher grades of recovered paper for paper recycling in EU mills and in third countries.

CEPI and ERPA were actively advocating for separate collection of paper as many countries were in the stage of transposing the Waste Directive into national legislation.

FINAT promoted, together with various partners, a Europeanbased recycling solution in Austria as an alternative for an existing outlet overseas. This initiative came on stream in 2010. FINAT’s efforts to find partners for the collection, desiliconisation and recycling of paper release liners and to raise awareness within the market about the availability of recycling solutions continue.

Ecodesign INGEDE was in charge of the preparation of a database about removability of adhesive applications and the development of a scoring system.

INGEDE negotiated a cooperation agreement with Digital Print Deinking Alliance (DPDA) in order to carry out at least one common project per year.

The national magazine publishers’ association in the UK, PPA, has continuously exceeded the Government’s target of a 70% recycling rate and renegotiated its agreement with Defra to better reflect the industry’s clear emphasis on environmental policy. This has enabled PPA to invest in further initiatives aimed at mitigating the environmental impact of producing magazines.

The French publisher Lagardère Active has implemented a policy of responsible management of paper throughout the chain, from the purchase of certified paper to recycling, optimising magazine sizes and weight and reducing unsold issues by adjusting the quantities supplied and recycling what is not sold.

Monitoring Report 2010

FEICA made a second survey confirming that DiBP has by and large been phased out by the adhesives and sealants industry for use in the manufacture of all paper applications.

Most ERPC members invested a significant amount of resources to solve the problem of mineral oil hydrocarbons migrating to food from packaging. While the paper and packaging part of the paper industry is actively taking steps to eliminate mineral oils in applications that it controls directly, the entire paper industry believes that eliminating the root cause of mineral oils in the paper recycling chain is the most efficient option.

The cooperation and commitment from all parties involved in the paper value chain is essential if we are to completely remove unwanted substances from the recycling system and meet our recycling goals.

Research and Development INGEDE contracted research institutes to carry out several projects in the field of recyclability. One was the survey of the removability of adhesive applications which was co-funded by ERPC members FEICA and FINAT, as well as by the German association bvdm. Another project dealt with the simulation of the deinking process in laboratory scale, particularly for the treatment of cross-linked and cohesive inks. A third project covered the quality of the loop water in deinking plants with respect to water-based inks.

INGEDE worked on a revision of several of their methods for testing recycled pulp and recyclability and issued two new methods.

FEICA, together with other partners in an EU-funded project, “Migresives,” developed a pragmatic, science-based concept to ensure consumer safety related to adhesives used in food contact materials. A freeware multilayer modelling software was developed and is available to all stakeholders and an extensive programme of workshops and training has been carried out.

CEPI, CITPA and FEICA are actively participating in a 4-year multi-sector EU project, “FACET,” which aims at producing realistic modelling of the exposure of consumers to substances present in food.

4

An Italian member of ETS, Lucart, has started up a €10 million line for “eco-tissue”. The first of its kind in Italy, the new line uses unbleached recycled fibres from used beverage cartons and produces comparable quality to virgin products. The technology allows the plastic and aluminium content in the containers to be recycled without the use of substances harmful to humans or the environment. This ‘Eco Natural Lucart’ project was recognised as one of the best projects for the Legambiente 2010 prize for environmentally-friendly innovation.

Education and Information Awareness raising on recycling is an important tool to ensure that European citizens are informed about the necessity of

recycling and become active supporters of the recycling process.

Numerous magazine publishers across Europe have organised awareness campaigns and sensitisation on this topic for their readers through editorial content and for all employees of their publishing houses. The information is not limited to recycling of printed magazines but gives advice on recyclability in general.

One example was in France where Lagardère Active organised public awareness campaigns in partnership with EcoFolio, the French producer responsibility organisation. Intergraf has actively supported recycling in various communications.

CEPI redesigned and revised the ERPC website at www.paperrecovery.eu

2006-2010 Growing Stronger as a Value Chain 2ND EUROPEAN DECLARATION: 14 SECTORS, 29 EUROPEAN COUNTRIES Preparation for end-of-waste criteria

Review of EN 643 starts

Adoption of Waste Directive

2006

2007

2008

ECHA Guidance on recovered substances

2009

2010

Guidance on REACH and recovered paper

1st European paper recycling awards

European de-inkability survey Recommendation to phase out DiBP

Monitoring Report 2010

De-inkability scorecard and calculator tool

Commitment to phase out DiBP

Adoption of Guide to Optimum Recyclability of Printed Graphic Paper and an Issue Sheet on De-inkability

Revised de-inkability scorecard and calculator tool

2nd European paper recycling awards

Survey on phase-out of DiBP

Preparation of an adhesive application database Study on de-inkability of UV inks

5

Paper Value Chain This flowchart illustrates the different tasks involved in paper recycling, creating the paper value chain. The manifestation of the paper value chain is the European Recovered Paper Council (ERPC).

Raw Materials

Cleaning / Screening

Pulping

Paper Making

De-inking

Inks

Additives

Pulping

Publishing

Printing

Converting

Sorting Long Term Storage

Recycling Recovery Consumer

Collecting

Product Usage

Disposal

Consumers (Industries, big commercial areas, offices, households)

Collectors of used papers Clean and sort used paper to produce raw material for paper recycling

and boards Paper and board producers (mills)

RECYCLED PULP Use recovered paper to produce NEW RECYCLED PAPER

RECYCLED PAPER

THE PAPER & BOARD RECYCLING CHAIN

Glossary - Consumption of paper and board: internal deliveries to particular countries plus imports from countries outside this list of countries.

- Europe: for the purposes of the Declaration, ‘Europe’ means the 27 EU member states plus Norway and Switzerland.

- Net trade in recovered paper: the difference between recovered paper exports to and imports from the defined area.

- Recovered paper: used paper and board separately collected and, in general, processed according to the European List of Standard Grades of Recovered Paper and Board (EN 643).

Monitoring Report 2010

- Recycling: the reprocessing of recovered paper in a production process into new paper and board.

- Recycled paper: new paper and board where fibres originate from recovered paper.

- Recycling rate: the ratio of recovered paper utilised for recycling including recovered paper net trade, and paper and board consumption.

- Utilisation: the use of recovered paper in a paper mill while producing recycled paper.

6

Europe & International

Uncoated Fine Paper

Corrugated

Bags & Coatings

Only the best quality feels this good.

ber one The num ser paper: colour la

quality st print e h ig H ity • runnabil e e fr le • Troub eutral • CO 2 n

Color Copy. The highest paper quality is an important requirement for perfect print results. Feel the smooth and pleasant surface of the Original and participate to win great prizes at: www.colorcopy.com

SOLUTIONS. FOR YOUR SUCCESS. www.mondigroup.com/colorcopy www.colorcopy.com

53810_Mondi_CC_210x297_engl_bulletp_PLWCI.indd 1

17.01.11 15:52