Pulp, Paper & Logistics Jan/Feb 2024

VOLUME 14 NUMBER 82

JANUARY/FEBRUARY 2024

See pages for new 22-29 G Packag reen ing section

INDUSTRY NEWS: Joint project to develop emission-free pulping processes

ABB

VALMET

PACKAGING

Tissue converting is now part of Valmet’s offering

Valmet has acquired Körber’s Business Area Tissue, a global supplier of tissue converting and packaging lines. We are happy to welcome the market leader in tissue converting and close to 1,200 dedicated new colleagues to Valmet.

Together, we offer unique benefits for tissue producers through the combination of our technologies, automation solutions and services. We also have an opportunity to develop our tissue customers’ processes further by combining data from the tissue making and converting processes.

Our experts around the world are committed to moving your performance forward – every day.

Explore our combined tissue making and converting offering www.valmet.com/tissue

IN THIS ISSUE IN THIS ISSUE

COMMENT

W

elcome to the January-February issue of Pulp Paper & Logistics, the first for 2024.

As we enter another year of publication, it’s clear that the continued growth of tissue and packaging grades of paper and board is showing no signs of slowing. That was reflected in the magazine’s re-registration process last year, during which we received increasing numbers of requests to include news from our sister title Green Packaging International.

I’m pleased to say that from this issue Pulp Paper & Logistics will include the latest news in a dedicated section that reports how fibre-based products are leading the way in the trend towards more sustainable packaging.

There is plenty of other positive news as well, covering issues such as how paper makers are working to reduce, and eventually eliminate, carbon emissions, and to address the need for maintaining the environment while using wood products.

Looking ahead, we have the Pulp & Beyond show in Helsinki, Finland, on 10-11 April to look forward to. If during your visit you would like to discuss either news submissions or advertising please contact me as soon as possible. Later this year we also have MIAC in Lucca, Italy, from 9-11 October which specifically addresses all things tissue related.

In our next issue for March-April we will be covering the following subjects: water and energy consumption management; energy recovery processes; mill management and software technology; plus a preview of the Pulp & Beyond show. News submissions should reach me no later than 11 March and advertising bookings by 15 March.

INDUSTRY NEWS LOGISTICS Eldorado Brasil uses Konecranes equipment in Latin America’s largest port

ABB

Take control of product quality and sustainability with advanced automation solutions

VALMET Enjoying the rewards of smooth cooperation

ATRADIUS UK The biggest trends in the pulp and paper industry

GREEN PACKAGING Pringles tube ‘designed for recycling’ in relaunch

ISSN 2045-8622 (PRINT) PUBLISHER & EDITORIAL DIRECTOR Vince Maynard Tralee, Hillcrest Road, Edenbridge, Kent, TN8 6JS, UK Tel: +44 (0) 1732 505724 Mobile: +44 (0) 7747 002286 Email: pulppaperlogistics@virginmedia.com

CONSULTANT EDITOR David Young Tel: +44 (0) 1737 551687 Mobile: +44 (0) 7785 796826 PRODUCTION Anthony Wiffen Tel: +44 (0) 1460 261011 Mobile: +44 (0) 7851 612799 Email: anton_print_1@mac.com

12 16 20 22 30

PROJECTS & CONTRACTS

32

PEOPLE

40

Front cover: Industry News, Emission Free Pulping, page 2

EDITOR John Nutting Tel: +44 (0) 1732 868071 Mobile: +44 (0) 7860 221486 Email: johnnutting47@gmail.com

10

PRODUCTS & SERVICES

Vince Maynard, Publisher and Editorial Director

Vol. 14 Issue No. 82, January/February 2024

2

PRINTER KNOCK OUT PRINT +44 (0) 1892 823540 Unit 2 The Coppice, Petteridge Lane, Matfield, Kent TN12 7LP info@knockoutprint.co.uk http://www.knockoutprint.co.uk

2 INDUSTRY NEWS

Pulp Paper & Logistics

Joint project to develop emission-free pulping processes

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ith the aim of ‘significantly’ reducing biomass burning and increasing the product yield of wood material used for pulping, a €15 million project has been set up under the joint leadership of VTT Technical Research Centre of Finland and RISE Research Institutes of Sweden.

The Emission Free Pulping programme has attracted support from five pulp and paper technology companies, to bring knowledge of industrial relevance and operations as well as a financial contribution. Andritz, Arauco, Metsä Group, Stora Enso, and Valmet have committed to a five-year collaboration with research organisations and universities.

The programme has been

Johan Engström: “Andritz is one of five companies supporting the Emission Free Pulping project”

granted substantial funding from Business Finland, amounting to more than €5m over a three-year period.

In due course the programme hopes to achieve emissionfree pulping (particularly

carbon dioxide emissions), and significantly reduce water usage in the processes.

Atte Virtanen, vice president of biomaterial processing and products at VTT, commented: “Due to the limited nature of forest resources, the growth opportunities for the industry are constrained. Moreover, the burning of biomass in the pulping process results in the emission of biogenic carbon dioxide. To significantly enhance resource efficiency and increase the value

Katariina Kemppainen, senior vice president of group R&D at Metsä Group: “deeply committed to the vision” January/February 2024

added from wood, revising the chemical processes and unit operations used in the pulping process is essential.”

Katariina Kemppainen, senior vice president of Group R&D at Metsä Group, added: “We are deeply committed to the vision of a thriving forest-based ecosystem that delivers the full value of Nordic wood. The key to achieving this lies in fostering innovation and coming together as an industry and as a research ecosystem.”

At Stora Enso, Mikael Hannus, senior vice president of group innovation R&D, said: “We celebrate that other companies and universities share our view on the necessity to use science and joint research for enabling significant improvement of the material yields from pulping and thereby reducing emissions.”

The Finnish public funding enables the hiring of the initial group of scientists that will be expanded with further funding from the companies involved. The goal is to form a group of 10–20 researchers focusing full-time on advancing the research agenda collectively agreed upon by the consortium.

INDUSTRY NEWS 3

Pulp Paper & Logistics

Pan Pac’s cyclone-hit mill in New Zealand is being upgraded

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year on since the Whirinaki pulp mill of Pan Pac Forest Products in New Zealand was hit by Cyclone Gabrielle, reconstruction work continues.

Danny Eagleton, Pan Pac’s technical manager, says Pan Pac’s owner Oji Holdings was adamant from day one that the site would be rebuilt and indeed improved.

“This catastrophe has actually enabled us to bring forward some key projects,” said Eagleton.

This was despite silt having flooded into buildings, causing significant damage to the plant when it was inundated in February 2023. In many areas on site the water was two metres deep.

Whirinaki is a BCTMP mill with an annual capacity of 280,000 tonnes. It is located close to Napier on the North Island and has been running for 50 years. In 2012, a state-of-the-art screening and bleaching plant to produce the BCTMP grade was added.

The wood raw material is Radiata pine, which enables Pan Pac to produce its world-leading high bulk softwood BCTMP at two freeness levels: CSF 350 to 400, and 300 to 350, aimed at different applications largely for Asian markets.

Eagleton said that there was

Pan Pac’s BCTMP pulp mill in New Zealand will soon re-enter the market with a new PulpEye system delivering improved fibre and pulp quality. Photo: Pan Pac still “a bit of work to do, and completion and commissioning activities are well under way” for both the pulp mill and lumber operations in the first quarter of 2024.

As part of the mill’s recovery efforts, PulpEye was selected to provide a state-of-the-art on-line fibre analyser equipped with modules for freeness, fibre, and shives measurements,

replacing an older analyser that was destroyed in the flood. And further opportunities are being considered for the future.

“We are delighted that Pan Pac decided to invest in a new PulpEye to be installed early 2024,” says Paul Watson, PulpEye’s representative in New Zealand.

“One reason for buying a PulpEye was the opportunity to later add more modules and to integrate

our PulpOnTarget software solution to utilise process data to increase efficiency, reduce operating costs, and deliver an even more consistent quality”.

“Pan Pac’s BCTMP pulp will soon re-enter the market and with our new PulpEye delivering fibre and pulp quality data we will ensure that high quality pulp is delivered to our customers from day one,” says Eagleton.

In brief l Sappi has stopped production at its Lanaken integrated paper mill in Belgium. Production ceased during December and the closure of the site is expected to

be completed before the end of March 2024. The mill had pulp production capacity of 165,000 tons per year, used to produce 530.000 tons per year of coated

wood-free paper mostly sold into the European print market. Sappi had already started a consultation process covering the future of the 581 workers at the mill. Sappi said

that its strategic focus includes reducing exposure to the graphic paper segment while expanding its presence in packaging, speciality papers, pulp and biomaterials.

January/February 2024

4 INDUSTRY NEWS

Pulp Paper & Logistics

International Paper closes Texas containerboard mill and two pulp machines

I

nternational Paper (IP) is reducing its pulp and paper making capacity in North America to “to further strengthen and optimise its manufacturing system to meet customers’ needs”, as sales and profit slipped in the third quarter of last year.

The paper maker announced in October that it would be permanently closing its containerboard mill in Orange, Texas, and will permanently cease production on two of its pulp machines: the #20 machine in Riegelwood, North Carolina and the #4 machine in Pensacola, Florida, with the loss of about 900 jobs.

“Decisions like these are extremely difficult, because of the impact on our

employees, their families and the communities in which we operate,” said chief executive Mark Sutton. “We are grateful to our employees in Orange, Riegelwood and Pensacola for their significant contributions to the company over the years.

We are committed to providing severance benefits, outplacement assistance and more to help employees during this time.”

The closure of the Orange mill will reduce the company’s yearly containerboard capacity by about 800,000 tons. IP’s remaining containerboard system in North America will include 17 mills with an annual capacity of 13 million tons. The closures in Pensacola and Riegelwood will reduce IP’s annual pulp capacity by around 500,000 tons (300,000

IP chief executive Mark Sutton: “Decisions like these are extremely difficult” tons fluff pulp and 200,000 tons southern bleached softwood).

The company’s remaining pulp mill system will comprise eight mills with an annual capacity of

2.7 million tons.

“We believe strongly in the attractive, long-term fundamentals of our businesses and these actions further strengthen our competitive platform. Our optimised mill system, with its broad capabilities, gives us the flexibility to meet our customers’ needs today and in the future,” said Sutton’ IP expected the Orange mill and the #20 machine in Riegelwood to cease production by the end of 2023. The #4 machine in Pensacola is currently idled and will not resume production.

Sales at IP in the third quarter of 2023 were US$4.61 billion, down from $5.4bn in the same period a year earlier, while net profit fell to $165m from $951m.

‘Great anticipation’ for Zellcheming Expo 2024 Organisers of the next Zellcheming Expo, being held over three days from 18-20 June 2024 in Germany, say that there has been ‘great anticipation’ for the pulp and paper industry event, based on response from last year’s show.

That attracted 2,700 visitors and around 150 exhibiting companies, while sponsors and partner companies offered a wide range of opportunities for intensive technical information exchange as well as uncomplicated networking.

More information at www. zellcheming.de January/February 2024

More than 150 exhibiting companiess from the pulp and paper industry attended last year’s Zellcheming Expo

INDUSTRY NEWS 5

Pulp Paper & Logistics

Sonoco backs the UK’s extended producer responsibility legislation

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K packaging manufacturers should work towards the original deadlines set for extended producer responsibility (EPR) legislation, even though the government has relaxed pressure on the larger producers to meet the targets, says leading paper packaging producer Sonoco.

The government had set firm deadlines for EPR, seeking to boost recycling rates in the UK, and to reduce the amount of waste going to landfill and for incineration.

These were 1 October 2023 and 1 April 2024 for large and small packaging producers respectively to enrol and submit data approaches.

Although a recent Regulatory Position Statement (RPS) confirms that no legal enforcements will be taken for businesses registered in England and Scotland as long as the data is submitted by 31 May 2024, companies are still being encouraged to meet the original deadlines where possible.

Sonoco has contributed to

Francesco Giannolo, general manager at Sonoco Consumer Products Europe: “a degree of nuance and flexibility is crucial,” he says the EPR consultation process and says it continues to engage with officials and wider industry stakeholders to scrutinise the detail of the legislation and to help shape a vision for the future.

The company’s white paper on the topic, first published in 2022, analyses what it means to be a responsible producer and examines the many ways in which the UK could improve its packaging recycling rates, going far beyond the scope of the proposed EPR legislation.

“Though the UK Government has recently pushed back its first

hard deadline for large packing producers to enrol and submit data approaches, it’s vital that the industry as a whole maintains full engagement and awareness,” says Francesco Giannolo, general manager at Sonoco Consumer Products Europe.

“Our aim right throughout this process has been to encourage as many stakeholders as possible to inform and involve themselves in the process, as we work towards the vision we all share – a vision of a more sustainable future for the packaging industry. Our white paper was a crucial part of this strategy, and it remains a valuable educational resource for the industry.”

Sonoco’s white paper offers a background into the current recycling landscape in the UK – and addresses some of the challenges and trends, including a ‘postcode lottery’ and the lack of consistency around the country when with recycling processes and accepted materials.

The subject of waste exports is also addressed – including the

Pulp & Beyond highlights global responsibility of forest products Leading brand owners will be contributing the theme of April’s Pulp & Beyond 2024 Conference at the Helsinki Expo and Convention Centre: ‘How the forest industry is contributing on global responsibility’.

The conference will take place on Tuesday 9 April as part of the leading international

forest industry event, Pulp & Beyond 2024, which runs from Wednesday to Thursday, 10-11 April 2024. On Friday 12 April 2024 there will also be excursions for professionals to Central Finland and for university students to Stockholm.

The panel discussion at the opening of the conference will

feature Michael Carus, the founder and chief executive of Nova-Institute, discussing the role of wood in the renewable carbon concept. Tiina Pursula, who is chief of sustainability and packaging materials at Stora Enso, will provide insights from the perspective of forest companies on responsibility,

worrying lack of accountability for how this waste is disposed of, and the fact that it is becoming increasingly difficult to find export destinations that will accept it.

The environmental impact of food waste is also explored: from barrier films to preserve shelf life, to the easing of emptying to ensure the least amount of food waste is disposed with its packaging.

Giannolo concludes: “We’re in complete agreement with the overall intent of the EPR legislation, but a degree of nuance and flexibility is crucial.

“To build a true picture of what a ‘responsible producer’ looks like, there is a lot more to consider than the type of packaging material they use. Creating recyclable packaging is important, but it is just one aspect of being responsible and sustainable.” ● Pringles composite snack containers, which have long been made from cardboard with a tinplate end, have been redesigned by Sonoco to be all cardboard. See Green Packaging International in this issue. and Lyndsey Parette, Nestlé Nespresso’s Nordic environmental sustainability manager, will share a brand owner’s perspective on global responsibility and the forest industry’s role in it.

After the opening, the conference programme will be divided into three tracks including presentations from top experts.

Each track will feature three or four presentations from three different perspectives or themes.

The complete programme is at www.pulpandbeyond.com.

January/February 2024

6 INDUSTRY NEWS

Pulp Paper & Logistics

Suzano marks its centenary with $100m investment to reverse nature loss

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razilian pulp producer Suzano is to mark its centenary in business with an initiative designed to advance global efforts to protect and restore nature.

Over the next ten years, US$100 million will be spent by Suzano, with an initial $30 million put into a series of global partnerships designed to accelerate research and education in conservation, climate change, and corporate sustainability, with a particular focus on Brazilian ecosystems, and to help drive forward private sector strategies and action on nature.

Commenting on the plans, Suzano’s chairman David Feffer said: “After 100 years in business,

we have learned to take a longterm perspective and plant the seeds today for the future we want to achieve. Through this initiative and the new partnerships we are forming, we hope to help create and empower the next generation of experts and leaders that will help governments, companies and civil society to take action to protect and restore nature over the next century.”

Suzano is one of the world’s largest private sector landowners, managing around 16,000 sqkm of eucalyptus farms in Brazil, alongside 10,000 sqkm of conservation areas across some of the country’s most biodiverse ecosystems.

The company’s tree farms

provide the raw materials for products such as tissue, toilet paper, books, packaging, diapers, and period products.

In 2020, Suzano set a series of long-term sustainability goals which include: connecting 500,000 hectares of fragments of Brazil’s Amazon, Atlantic Forest and Cerrado biomes with ecological corridors by 2030; net removal of 40 million tons of carbon dioxide from the atmosphere by 2025 after taking into account the company’s full value chain emissions; and lifting 200,000 people out of poverty in its areas of operations by 2030.

Suzano has signed a memorandum of understanding (MoU) with the University of Cambridge, and a separate MoU

with the Stanford Doerr School of Sustainability at Stanford University. These are expected to be the first of multiple partnerships formed with universities under the initiative, in Brazil and around the world.

Feffer continued: “We believe that education, science, and effective collaboration are three of the most powerful weapons we have to fight back against the dangerous decline in species, degradation of soils, and pollution of our waters and atmosphere. There is no time to delay, the world must halt and reverse nature loss by 2030. Our ambition is to start now, and have a vision for how we can be part of the solution for the next century.”

Mondi’s Neusiedler mill to cut greenhouse gas emissions

Saica acquires Ecovidal to strengthen its presence in Spain

Mondi has revealed more details of the €20 million investment it is making at its Neusiedler uncoated fine paper mill in Lower Austria to increase efficiencies, reduce greenhouse gas emissions and increase operational safety.

Sakari Eloranta, technical director for uncoated fine paper at Mondi explains: “These upgrades will help Mondi Neusiedler to reduce the pulp mill´s greenhouse gas emissions by over 20 percent, while also reducing NOx emissions by up to 10 percent and gas consumption by around 25 percent.”

The investment programme includes upgrades of the recovery boiler, pulp dryer, steam accumulator

Saica Group has agreed to buy Spanish waste management and collection company EcovidalMiguel Vidal e Hijos. The value of the all-share deal was not revealed.

Local subsidiary Saica Natur says that the move strengthens its presence in the Henares corridor, an important business, industrial and residential area north-east of Madrid.

January/February 2024

and steam turbine at the pulp mill in Kematen an der Ybbs, where Mondi Neusiedler produces sulphite pulp.

Most of the mill´s energy comes from steam generated by a recovery boiler. The objective of the technical upgrades is to increase the boiler’s efficiency. Any surplus steam will be used for the pulp dryer, which previously used natural gas as an energy source, and thereby will be operated emissions-free in the future. A further benefit is that the turbine will be able to generate more ‘green’ electricity from the additional steam output.

The investment programme is expected to be completed by the end of 2024.

Ecovidal has 25 employees and in 2022 had a sales of 10 million euros. It manages up to 53,000 tonnes of waste a year, 92 percent of which is paper and cardboard.

Located in Torrejón de Ardoz with a 16,000 sqm warehouse, Ecovidal has been supplying recycled paper to Saica Paper’s mills for more than four decades, establishing a long-standing business partnership.

In brief

l ABB and Canada’s export credit agency (EDC), have signed a global partnership to promote investments in strategic

electrification and automation projects in Canada and around the world, with funds available of up to US$ 2.9 billion.

INDUSTRY NEWS 7

Pulp Paper & Logistics

Mondi commits to making more saturating kraft paper

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ollowing Mondi’s investment in a new paper machine at its Štĕtí plant in the Czech Republic, the UK-based firm says it is increasing production of saturating kraft paper, so that it can improve its service to manufacturers of internal and external building panels, worktops, furniture and technical films.

Capacity will be optimised throughout Mondi’s mill network, providing more capacity for its saturating kraft, called Advantage MF

Boost, at the Frantschach mill in Austria and the Dynäs mill in Sweden.

Both Frantschach and Dynäs mills are well placed to deliver short lead times across Europe and provide customers with reassurance of good service and production back-up, says Mondi.

Mondi says it has further improved the efficiency of its paper machines running the saturating kraft paper, giving enhanced formation, better drying properties and faster production. Ongoing R&D

has also meant this quality paper is available in a larger product range, with lower and higher grammages to suit each individual customer need.

Mondi’s Advantage MF Boost is ideally suited for laminates due to its porous properties: the unbleached and natural brown kraft paper is created with responsibly sourced fresh fibres in Sweden and Austria.

Its long fibre pulp makes it highly absorbent, ideal for taking in and acting as a carrier for resin used to adhere the layers, essential to the final

laminate’s performance.

Roman Senecky, operations chief for kraft paper at Mondi says: “We are very committed to boosting production of our Advantage MF Boost in order to serve the markets for decorative and compact laminates as well as industrial and technical films for plywood. Our existing infrastructure means we can produce and deliver this essential porous kraft paper globally, in suitable quantities, providing a reliable supply to all our existing and new customers.”

January/February 2024

8 INDUSTRY NEWS

Pulp Paper & Logistics

More R&D investment from ABB in Europe

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s ABB’s Czech Republic-based European Regional Execution Center (EUREC) celebrates 10 years of project management and strategy support to pulp and paper teams, last year it undertook a major expansion that will offer a broader geographical scope to increase

operational efficiency, in addition to the recently expanded R&D centre in Dundalk, Ireland.

To further deliver enhanced coordinated resource planning across Europe, dedicated jobs have been created including the recent appointment of Pamela Murphy as Europe operations manager for pulp and paper.

“The expansion will benefit our pulp and paper customers in Europe by ensuring continued high-quality project outcomes no matter which country in Europe the paper mill is located, through the application of common leadership processes and tools.

Local service teams will be better supported by a centrally

Paper makers feature in Time’s World’s Best Companies rankings Four global pulp and paper manufacturers were listed amongst the top 800 companies in Time magazine’s World’s Best Companies listings for 2023.

Finland’s Stora Enso Oyj was the highest listed in the industry at 325th with a rating of 83.38, but was down from 225th in the previous listing, based on work by Statistica for Time magazine.

Ireland’s Smurfit Kappa Group January/February 2024

came in at 414th with a ranking of 82.08 but down from 338th.

Smurfit Kappa was also listed in the top 100 companies by Sustainability magazine.

Market researcher Statista’s World’s Best Companies list is an independent acknowledgment of significant achievements in employee satisfaction, revenue growth, and sustainability. An inclusion is based on strong scores

across extensive employee survey results, revenue growth, and data points related to environmental, social and governance (ESG) issues.

Other pulp and paper manufacturers in the World’s Best Companies listing were the UK’s Mondi at 469th (369) with a rating of 81.23 and the UK’s DS Smith at 591th with a rating of 79.01.

For comparison, the highest

managed group of experts,” said Stefano Cinquina, ABB’s global business line manager for pulp and paper.

“Our priority is to continuously build and sustain our application know-how to better serve the industry, and this expansion will be a big factor in that success and the build-up of knowledge.”

rated food or drinks company was Coca-Cola at 67.

Commenting on the listings Time magazine said: “Tech companies performed well, alongside IT and consulting firm Accenture and financial-services company American Express, in part because their carbon emissions are so much lower than other types of companies with significant physical footprints like airlines, hotels, or big manufacturers. But they also ranked well because their employees are largely happy.”

INDUSTRY NEWS 9

Pulp Paper & Logistics

COMMENT

Pulp and paper makers are innovating their way out of CO2 emissions, says Cepi

T

he pulp and paper sector has already decoupled growth and CO2 emissions for several decades, but it remains energy-intensive. To go even further in its commitment to climate change mitigation it bets on breakthroughs in an array of technologies, which could reduce the sector’s energy needs by as much as 80 percent, and on a formidable potential to install renewable energy directly on-site. A recent acceleration in progress has been spurred by unprecedented collaboration amongst industry actors.

Cepi represents European pulp and paper manufacturers. It leads a network of innovative solution providers and bootson-the-ground experts, called the Energy Efficiency Solutions Forum, or EESF. It includes engineers working across Europe for companies and suppliers in the sector.

Their aim is to accelerate the development and implementation of emission-

reducing technologies, identify obstacles to their deployment and to advocate for a favourable regulatory environment. Recently, the EESF has collaborated with the heat pump industry and its EU association, and laid the groundwork for heat pumps to be integrated in Europe’s paper mills.

Heat pumps have the potential to provide about 50 percent of the energy required for heat and, in the same process, help to lower their carbon dioxide emissions.

Additionally, a recent study found that 30 percent of electricity and almost 6 percent of heat generated on-site could by 2030 come from solar or wind energy.

Still, the largest gains in reducing emissions will come in the near future from reducing manufacturers’ energy needs in the first place. Bets are still off on which technology identified by the EESF will eventually be the expected game-changer.

Superheated steam technology transforms paper mills into large, closed circuit heat pumps. Novel drying systems allow for the

water in the paper web to be removed without the use of heat and evaporation, and waterless paper production would entirely remove the need to apply heat.

One of these technologies will eventually become the breakthrough which will allow the sector to significantly reduce its carbon dioxide emissions.

Apart from the EESF, several other consortia in Europe are exploring the potential of energy efficiency solutions, as they offer the higher ‘decarbonisation per euro spent’ and aim to tackle the ‘hard problem’ of the amount of heat needed to dry paper. Heat alone represents about 70 percent of energy needs in a paper mill.

One such group is the German Modellfabrik Papier, a ‘model factory’ which will soon house researchers and academics focused on one goal: climateneutral paper production by 2045.

It is supported by 24 companies and seven research centres, as well as Cepi itself and its German counterpart Die Papierindustrie.

Another is the VTT Technical

Research Centre of Finland Ltd, launching a mission-based research programme called Energy 1st – Fibre product forming, involving more than 40 companies.

This programme will demonstrate an innovative ‘dry forming’ process in a pilot infrastructure. [VTT is also involved in the Emissios-free pulp project: see news elsewhere in this issue].

Compared to other sectors, pulp and paper manufacturing makes substantial annual investments into the greening of its production processes. This comes with a certain number of near misses, which is why evaluating the business case for a new technology is an essential part of the process.

A recent study of ‘deep eutectic solvents’ aiming to decarbonise pulp making at the source has not had the results expected. But it led to breakthroughs into the production of lignin, which could be a major source of revenue for the industry in the near future, as an alternative to fossil-based materials.

NAF valve business acquired by Andritz US-based Flowserve Corporation has agreed to sell its Swedish NAF AB business to Andritz.

NAF AB designs and builds Flowserve’s NAF control valve portfolio and is a leading supplier with experience in providing process control valves for pulp and paper and other related industries.

The acquisition, the value of which was not revealed, was expected to

be completed in the first quarter of 2024.

With 50 employees at a facility in Linköping, NAF has been a successful provider of process control valves for more than 100 years.

The acquisition further extends and strengthens Andritz’s product and service portfolio in the field of process control by adding

control valves to its portfolio of process actuators, analysers, and measurement equipment for the pulp and paper making process. For many years, Andritz has successfully equipped its production plant and equipment deliveries with NAF control valves.

Jarno Nymark, Andritz’s board member responsible for the pulp and paper business, says: “I look

forward to welcoming the NAF AB team to the Andritz Group. Their control valves are an important element for the operation and optimisation of process plants and hence a valuable addition to our process control product portfolio. We are excited about the opportunity to expand NAF AB’s sales and service capabilities by leveraging our global presence.”

January/February 2024

10 LOGISTICS

Pulp Paper & Logistics

Eldorado Brasil uses Konecranes equipment in Latin America’s largest port

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even forklifts and two gantry cranes have been delivered to Eldorado Brasil’s new cellulose terminal at Port of Santos by Konecranes.

The completion of the order also involved joint planning and consultation on the layout of the terminal.

The new terminal at Latin America’s largest port is designed to annually process three million tons of pulp bales – or about 8,300 tons a day – by rail and truck. Around 90 percent of the pulp is exported worldwide to 45 countries.

Eldorado approached Konecranes for support in planning the layout of the terminal and to provide the specialised equipment for its operation.

Commenting on the project,

January/February 2024

Leandro Nogueira, logistics operations manager at Eldorado Brazil, said: “We want to be the benchmark in cellulose logistics, so we chose Konecranes – the benchmark in material handling – for our new terminal. They helped us design the terminal and provided equipment with all the special adaptations we require for cellulose handling. After just a few months, we’re already impressed with the productivity, safety and eco-efficiency.

“Eldorado came to us after using a Konecranes indoor overhead crane at another pulp mill for over a decade. With this terminal, we offered them a complete pulp handling solution, and we will continue to offer such full-service support in the future.”

Andrés Ramirez, regional

sales manager for lift trucks at Konecranes added: “This delivery strengthens a long partnership with Eldorado that offers many benefits to both sides, including extensive cooperation with our trusted local lift trucks distributor Equiport.

The new cellulose terminal is a state-of-the-art digital ecosystem that brings the highest levels of efficiency and safety to lifting in the pulp and paper industry, and we’re proud to support Eldorado in making it a success.”

The seven SMV 16-1200 C 16ton forklifts use a special clamp designed to lift pulp bales without pallets and have several safety enhancement features including shock absorbers and safety lights and cameras. Special sensors optimise oil usage and reduce waste.

One of the seven special forklifts delivered by Kronecranes to Eldorado Brasil’s cellulose terminal at Port of Santos The two gantry cranes are tailormade with a customised open winch, a spreader clamp for pulp bales and the option to attach a container spreader when needed.

A variety of Smart Features ensure smooth and accurate movement, and braking energy is recycled.

Radio controls and a Remote Operating Station (ROS) allow full crane control with maximum operator safety.

Konecranes is also providing Eldorado Brasil with Truconnect Remote Monitoring, which collects near real-time diagnostics to optimise the performance, maintenance and eco-efficiency of all the equipment.

LOGISTICS 11

Pulp Paper & Logistics

Transtar rolls out #JolodaExpress trailers to transport paper

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s part of German logistics specialist Transtar Group’s expansion to support a more diverse range of markets and loading systems it identified the transportation of paper rolls and pallets.

To manage the handling of larger cargoes it ordered a new trailer fleet that could streamline the loading and unloading of cargo while meeting specialised handling requirements to prevent damage. The trucks were equipped with the Skate & Track system from UK-based Joloda Hydraroll to support more efficient road freight operations across Europe.

Traditional loading and unloading methods involving forklift trucks presented various drawbacks, including the risk of product damage and limitations in space utilisation. Transtar Group, founded in 2016, turned to its preferred trailer-builder manufacturer for a design that would not only overcome these challenges but also increase overall efficiency and reduce maintenance requirements.

With more than 250,000

systems operating in more than 30 countries, the Skate & Track system offers smooth transportation of paper reels and pallets in trailers. Transtar Group opted for a fleet of 150 trailers fitted with the system, including heavy duty skates that are capable of lifting and handling loads of up to 3.5 tonnes per pair.

To install the system, four steel tracks are fitted to each trailer, recessed longitudinally into the floor. These tracks serve as the foundation for the Skate & Track system, as they allow the skates to roll under the cargo. The skates feature a lever mechanism that lifts the cargo onto rollers, enabling easy movement along

Transtar’s #JolodaExpress trailers are fitted with Skate & Track systems to handle paper rolls and pallets

the length of the trailer. Operators can use the system to push pallets inside the truck to load or pull them towards the rear to unload.

For securing cargo to the trailer while in transit, the tracks feature strategically placed holes at floor level to accommodate system accessories such as chocks or lashing hooks.

The Skate & Track system is suitable for a wide range of cargo types, including pallets, slip sheets, drums, newsprint rolls, or heavy machinery. Its ability to handle cargo without forklift trucks has streamlined loading and unloading processes, reducing the amount of time truck drivers must wait, thereby improving delivery schedules.

Eliminating the need for forklifts in the cargo space has also reduced the risk of accidents, product damage, and damage to equipment such as forklifts and trailers. The weight capacity of the heavy duty skates ensures that even the heaviest loads can be managed with ease and efficiency.

Additionally, the Skate & Track system is specially designed so that cargo can be tightly loaded.

This ensures the load remains

stable and secure during transport while making the best use of space inside the trailer, thereby reducing the overall number of trips per truck. The system has a self-cleaning mechanism that minimises maintenance and associated downtime.

Transtar Group says the decision to use the Skate & Track system has increased the efficiency and reliability of its service.

The group claims to be the quickest Joloda Hydraroll transport service provider in mainland Europe, branding its trailer fleet the #JolodaExpress.

Sergej Pautschkow, managing director of Transtar Group, commented: “Our Joloda Hydraroll trailers have proven invaluable in our pursuit to help more clients achieve their business goals.

With the efficiency, reliability, and versatility of the Joloda Hydraroll Skate & Track system, we’ve not only optimised our logistics but also earned the trust of our clients. It’s a partnership that reflects our commitment to excellence and the success of our clients’ endeavours.”

More information from www. joloda.com or www.transtar.de/ January/February 2024

12 ABB

Pulp Paper & Logistics

Take control of product quality and sustainability with advanced automation solutions

P

aper manufacturing is one of the most complex industrial processes in the world. Quality requirements of the finished product coupled with production rate changes, especially in a low demand market environment, mean operators need modern, effective measurement and control techniques to deliver onspecification paper economically and efficiently.

Papermakers require visibility of the sheet’s properties as

January/February 2024

Quality control systems are evolving beyond established online properties and now offer papermakers visibility and control along the entire value chain, ensuring the product is delivered economically, efficiently and on-specification, as Andy Broomfield, Global Product Management – Quality Control Solutions at ABB, explains it is formed to reduce rejects and improve repeatability and runnability. By continuously making counteractive changes to dynamic process movements and disturbances, quality control systems (QCS) achieve reduced

variability and swift responses to set point changes, avoiding production losses, lowering emissions and improving product consistency.

Rather than simply reducing variability, modern QCS enable

automatic controls to optimise production processes and energy consumption, reducing waste and costs – all while ensuring that the final product meets both internal and external standards. Each paper machine using ABB’s QCS

ABB 13 ABB Ability Quality Management System (QMS) for improved quality control; a project in Brazil illustrating how QCS can drive sustainable operations; and why investment in research and development (R&D) and people are key to unlocking future innovation.

Quality is nothing without control

ABB’s QCS technologies have been successfully integrated into existing pulp and paper operations in customer sites worldwide can reduce production losses by 2 percent or more, equating to a reduction of 1,100 tons of CO2e emissions per machine, each year.

This article will explore QCS technologies in more depth and explain how they can be successfully integrated into existing pulp and paper (P&P) operations; ABB’s portfolio of QCS solutions, which form part of the

To those unfamiliar with P&P, the term QCS could be misinterpreted as meaning quality management in terms of pure statistics. Within the industry it is sometimes perceived only as a measurement scanner, the visible and tangible equipment.

In fact, it is a complete solution incorporating process and product observations as well as automatic controls. It continuously and dynamically calculates desired actuator set point changes, based on the process conditions and disturbances. In addition, it can include dedicated actuators to manipulate the process to achieve the papermakers’ objectives.

The objectives of papermakers have traditionally been established through pilot trials using extensive lab measurement and conversion performance validation. This finally establishes what is commonly referred to as “a grade recipe”. The set of desired product and process properties may vary depending on the P&P application segment, such as different board grades, dissolving pulp, tissue, and paper.

Using a more traditional QCS has meant trying to fix things at the end of the production line. For example, the moisture content of the paper can be controlled by changing the steam pressure, or the product weight can be adjusted by manipulating the stock flow, simply by being subject

Rather than simply reducing variability, modern QCS now enable automatic controls to optimise production processes and energy consumption, reducing waste and costs – all while ensuring that the final product meets both internal and external standards

to whatever disturbance is coming from upstream processes.

As a global technology provider with many decades of experience in quality control and automation, ABB is always looking for ways to leverage its portfolio of P&P solutions to offer customers additional value. The company’s KPM process measurement products measure total and filler consistency in the headbox flow and short circulation loop for superior quality control in the wet end of the production.

Moving upstream: QCS and sustainability ABB technologies now enable more rapid and precise fibre measurements as well as new ways to characterise morphology for easier product, process and quality optimisation.

In addition to better efficiency, productivity and product quality control, papermakers can also

add extra value by extracting data from the tester and conducting their own analysis. In all these cases, ABB’s main goal is to reduce variability of the fibre and furnish properties before the product enters the paper machine. This holistic view provides best overall performance both in steady state operations and transitions.

No conversation on the process industries is complete without mentioning sustainability. In the context of P&P production, producing a more sustainable product translates into reducing “over-quality”, getting the job done in the downstream value chain without spending on excessive raw materials; fibre, water and chemicals. That means using automated control systems to reduce variability, to allow reduction of raw materials and fossil fuel energy use (electrical power, steam), and improve circularity through reduced asset waste and increased asset lifespans.

As outlined, ABB helps paper mills reduce rejects by keeping the product properties within a target range throughout the papermaking process. This is accomplished through the ABB Ability QMS, which provides measurement and control to reduce variability – and therefore production waste. When paired with ABB Ability Advanced Process Control (APC), operators can further optimise process efficiency and raw material consumption to make on-spec products, economically and efficiently.

Measuring and visualising mechanical properties While sustainability is a priority for our customers, maintaining the desired physical properties in the product is equally important.

In the past, this was achieved by

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Pulp Paper & Logistics

January/February 2024

14 ABB

Pulp Paper & Logistics

calculating certain properties with a limited number of variables. It is now possible to derive these using advanced modelling techniques.

Modern distributed control systems (DCS) enable personnel to view consolidated process data and other useful information such as paper quality, machine speeds, furnish preparation and pulp mill in a user-friendly interface. This is an important advancement, enabling operators to visualise information that has been automatically curated, calculated and analysed in a way that was not possible in the past.

ABB QCS Measurement Performance, for example, notifies individual teams if a parameter on their part of the equipment is abnormal and also enables ABB experts to remotely log on and help the on-site team at the mill visualise the bigger picture and diagnose the issue before it affects production.

ABB QCS solutions also offer precise machine-direction and cross-direction measurement separation. This provides the most reliable multivariable machinedirection control and crossdirection control features.

Case study: Klabin, Brazil Klabin, a leader in the paper packaging segment in Brazil and a pioneer in the field of sustainable development, is deploying ABB pulp production solutions to improve operational efficiency in the production process and offer better, more green products to its customers.

As the only company the country to offer products for hardwood, softwood and fluff pulp, Klabin is prominent in the packaging and industrial bags markets. The company’s 23 industrial units have an annual production capacity of 4.2 million tons of market pulp January/February 2024

Customers are increasingly open to automation and digital systems that gather and analyse operational data and paper. Some of these utilise modern systems and tools that ensure best process optimisation.

For example, ABB’s QCS is used to

reduce variation in moisture and basis weight in the final products.

This allows maximised uniformity and highest product quality.

Precision sensing and tight controls reduce quality losses as well as fibre, water, energy and chemical consumption. Full

ABB 15

Pulp Paper & Logistics

ABB service support is provided for continuous updates of the latest control algorithms and measurement technology.

The QCS fits into the plant-wide DCS in each Klabin factory. The DCS manages, orchestrates and controls the production processes via multiple autonomous controllers distributed throughout the network that communicate and coordinate with each other to perform specific tasks. The automatic controls mentioned above, working through the DCS, enable high stability and quality. Any process deviation is automatically detected and can be analysed by experienced ABB technicians with access to all the relevant data. This level of scrutiny means that typical machine uptime is more than 99 percent, which makes it possible to produce a ton of packaging paper in just 29 seconds.

The importance of R&D and talent retention All the aforementioned capabilities are dependent on

Caliper sensors being demonstrated at ABB’s Dundalk R&D Centre in Ireland highly-skilled people across the talent spectrum, including control engineers, data scientists, modelling and simulation specialists, field service engineers and technicians. Speaking with colleagues and customers in the P&P industry, I sense a new openness to automation and digital solutions that gather and analyse operational data to optimise efficient, sustainable manufacturing, enabling

Moisture sensors being tested at ABB’s Dundalk R&D Centre in Ireland

papermakers to make informed decisions that add real business value.

Central to these efforts is research and development (R&D) – both in laboratory settings and during live field projects in partnership with existing and new clients. Attracting and retaining new data scientists and engineers to the industry is vital to ongoing successes and technology development. ABB’s new R&D

centre in Dundalk, Ireland, for example, has a training hub that provides both skills development support for ABB and its customers.

The company is also engaged in implementing digitalisation solutions such as artificial intelligence and machine learning to help workers operate equipment more effectively and efficiently, reducing the need for onsite technical support.

As mentioned earlier, the goal is to provide full optimisation of the P&P production process. In this sense, R&D is as much about people as it is about technology.

Meaningful investment in people to nurture and develop their domain knowledge is really an investment in tomorrow’s advanced technology.

In this way, ABB can help new and existing P&P customers integrate new QCS solutions into their operations, achieve more from their installed base by streamlining production processes and reduce downtime and waste.

Technologists will continue to work side-by-side with producers, supporting them to make the move beyond the physical and into the digital.

January/February 2024

16 VALMET

Pulp Paper & Logistics

Enjoying the rewards of smooth cooperation

N

aini Papers at Uttarakhand in India, started up its new cooking, fibreline, recausticising and lime kiln equipment supplied and installed

by Valmet in 2021. Although the project faced significant challenges because of the Covid-19 pandemic, the excellent cooperation between Naini and Valmet overcame these hurdles with a little creative problem solving. The new line has now been successfully producing high-quality pulp since the

January/February 2024

Key to the successful start-up of a new bleached hardwood kraft pulp line at Naini Papers in India three years ago was close collaboration with supplier Valmet. Since then the line has far exceeded the original daily capacity, as Hugh O’Brian explains very smooth start-up. Initially designed to make approximately 300 tonnes of bleached hardwood pulp per day, production capacity was quickly upgraded, and the plant can now easily make 370 tonnes per day.

Naini chose Valmet in 2019 as the main supplier of the key

process technology for making around 100,000 tonnes of bleached hardwood kraft (BHK) pulp per year. The expansion’s main aim was to use BHK pulp to augment the non-wood agricultural-based fibres Naini had previously been using. In addition, Naini was targeting

environmentally friendly fibre production that also resulted in low effluents and operating costs.

Concern about shortage of non-wood fibre sources Pawan Agarwal, managing director of Naini Papers, explains the rationale for the investment

VALMET 17

Eight Valmet TwinRoll presses are part of the production capacity upgrade to 370 bdt/d in wood-based pulping, having always relied on non-wood fibres in the past. “We had been an agricultural fibre-based paper mill since we started 25 years ago, mainly using bagasse and wheat straw as the main raw materials. But we were seeing less availability of these agro raw materials, and we realised there might eventually be a major shortage of bagasse and wheat straw. So that was our primary reason for building this line.

“We also wanted to increase our products’ overall quality and extend our product portfolio, and wood was a good alternative for achieving this. Finally, we wanted to add a new paper machine

based on wood pulp, so it made good sense to combine these aims and add this hardwood pulp line.”

The cooperation and teamwork between Naini Papers and Valmet has been excellent, says Agarwal – as he anticipated it would be.

“We selected Valmet based purely on merit, as they have some very good references in both India and abroad. We visited some sites and saw the technology running well, and we were impressed with Valmet’s existing fibrelines’ performance. We therefore chose Valmet as a natural partner for this fibreline.”

Smooth project management and start-up Mukesh Tyagi, technical director at Naini Papers, is extremely pleased with the investment’s

overall execution. “I’ve never seen a large project with such a smooth commissioning. We’ve had really positive experiences with everything – the fibreline, recovery, lime kiln and recausticising – based on excellent communication between the teams.

“We had no problems during the execution and commissioning, and I can honestly say that I have no negative feedback about the cooperation with Valmet – we got everything we asked for. Even their overseas engineers came promptly whenever we felt it was necessary, which we really appreciated.”

Looking specifically at the recausticizing operation, Sanjay Bhore, senior general manager of the recovery plant, is also very satisfied with the

equipment’s performance. “One of Valmet’s best solutions for our recausticising project is the white liquor disc filter, the first to be adopted in the agro-fibre business.

So there was initially some concern about how well it would work, but we were confident we would succeed.

“I can say that the support the Valmet team has provided has been wonderful. And the white liquor disc filter is performing extremely well here. We understand that the filter cloth must normally be changed after six months, but we’re running smoothly and haven’t changed it for fourteen. So the equipment is working very well.”

Fresh water consumption was a critical parameter for the project, with the target of less than 9.5

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Pulp Paper & Logistics

The expansion’s main aim was to use BHK pulp to augment the non-wood agro-based fibres January/February 2024

18 VALMET

Pulp Paper & Logistics

The batch cooking and fibreline delivery cubic metres per tonne of pulp, due to water restraints in the area.

Agarwal explains: “And I’m happy to tell you we’ve achieved close to nine, so it’s better than we targeted. And we’re now planning to bring it down further.”

Valmet’s local presence with top-level people and equipment is critical From Valmet’s perspective, Varun Jain, director for the India region, explains that several important factors supported the excellent success and cooperation between Naini and Valmet.

“In this project, we were able to utilise our very strong presence in India and our local supply capabilities, which we naturally combined with our state-of-theart fibre processing and kraft January/February 2024

recovery technology. And perhaps most important of all was Valmet’s experts’ world-class technical expertise in getting the equipment started and keeping it running smoothly and profitably.”

The upgrade to 370 bdt/d includes batch cooking and fibreline equipment from Valmet, with a digester plant and a fibreline comprising eight Valmet TwinRoll presses, a screen room, a four-stage bleach plant, MC pumps, mixers and tower scrapers, as well as the basic engineering and site services.

The recausticising delivery also includes the previously mentioned white liquor disc filter WL unit.

The new long wet lime kiln has a design capacity of 200 tonnes per day, with a chain system for

the drying of the lime mud inside the kiln. The kiln has a burner system designed either for firing producer gas in combination with furnace oil or for firing 100 percent furnace oil. Producer gas is a low-temperature, low-grade gas produced in a coal gasifier.

Reliability the biggest benefit Pawan Agarwal considers reliability to be the best benefit of Valmet’s machinery. “I must say the equipment’s reliability is impressive. The uptime is good, and fortunately we’ve had no big shutdowns or maintenance issues.

The overall technology is well proven. Valmet is always making improvements to this technology – and it shows.”

As would be expected, Covid

challenges were a hindrance in the execution phase, especially during the commissioning.

But Valmet and Naini together devised a plan to have regular online meetings, the technology of which had fortunately matured by then, allowing the teams to interact closely on each issue, not physically but online. There were some hiccups, but the start-up was still smooth, says Agarwal.

“Those frequent online meetings meant we really didn’t feel we missed the Valmet team’s physical presence. And I’d like to emphasise that Valmet was always very

VALMET 19

Pulp Paper & Logistics

supportive. Whenever we asked for a meeting, they were there, and we were never

asked to wait or to delay a particular process. So it went quite smoothly and covered a lot of things. It was exciting to commission such a big plant with online support.”

Fiberline automation extremely beneficial “We’ve had very good experiences with the new cooking plant. It started with zero spillage and no problems with pulp quality,” says Kuldip Maheshwari, general manager – Fiberline at Naini Papers. “We feel the preheating of the chips was a key factor that helped greatly in producing uniform pulp cooking and quality.

We really haven’t

had any big challenges in the cooking plant – it’s running well.”

Fibreline automation has also played a very valuable role in the operations. From day one, full automation has been used and has helped with the smooth commissioning. “The automation has been extremely beneficial, and we’ve run on 100 percent automation from the get-go, which is great,” says Maheshwari.

“And of course, when necessary, we had support from the Valmet team, who were always ready to help us.”

New speciality paper machine to start up in 2025 The Naini Group of Industries was founded in 1982, and Naini Papers started in 1995. It is one of the few premier paper manufacturing facilities in India,

“I must say that the start-up exceeded our expectations,” says Pawan Agarwal, managing director of Naini Papers Limited

Full fibreline automation has played a highly valuable role in the operations from day one offering high-quality writing and printing papers with excellent physical and optical properties.

The company has recently ordered a new speciality paper machine, PM3, from Valmet.

Like the fibreline, PM3 will also have state-of-the-art machinery, with some new technology in place. The paper machine project is ongoing, and commercial production is expected to start sometime in March 2025.

Pawan Agarwal concludes by again praising the BHK pulp line’s smooth start-up. “I must say that the start-up exceeded our expectations. I remember I was travelling from London to Delhi, and I was in touch with my team at 11.30 at night when they started the fibreline. And at two in the morning, we were making good pulp. It couldn’t have been any smoother.”

January/February 2024

20 ATRADIUS UK

Pulp Paper & Logistics

The biggest trends in the pulp and paper industry What will dictate developments in the pulp and paper industry in the coming 12 months?

James Burgess*, an insurance specialist in the paper and packaging sector provides some answers

I

t was a turbulent year in 2023, with the sector stabilising after a lockdownrelated peak, quickly followed by surging costs and supply chain challenges triggered by high interest rates, Brexit, conflict, and economic uncertainty.

Looking ahead to 2024, we’re anticipating huge shifts in how firms react to protect margins, safeguard their businesses, and respond to consumer and trade demands.

These are five trends I think will shape paper and packaging in 2024:

1. Protecting margins as the price of paper falls Between June 2020 and January 2023, paper prices almost doubled, with commodity shortages, energy prices, Brexit and surging freight costs feeding into rising prices.

At the same time, significant growth in e-commerce – driven by national lockdowns – brought an overwhelming increase in home deliveries. As demand soared, the price of paper did too.

While the price of manufacturing paper has stabilised this year amid weaker demand and falling energy prices, a faltering economy means that producers are reluctant to let go of elevated pricing.

In 2024, we will see paper and packaging manufacturers starting to ease prices, though high costs, supply chain challenges, and economic uncertainty may mean the benefit is not felt until the second half of the year.

2. Buoyancy in e-commerce While the high street used to be January/February 2024

a weekend fixture, we’ve seen big hitters, like Topshop and Wilkinsons, shut shops over the past five years as consumers flock to the comfort and affordability of next-day, one-click-driven e-commerce. This shift was put in super-speeded by the arrival of national lockdowns in 2020, which increased online spending by 48 percent year-onyear to UK£116 billion, according to Ofcom. The huge uplift in deliveries naturally created a new wave of demand for packaging materials.

While online retail sales fell by 0.3 percent in September MoM to 26.7 percent – sales remain buoyant and well above the same point in 2019 (18.1 percent). This buoyancy, within the context of evolving consumer demand and spending trends, means that we should see an opportunity for agile paper and packaging suppliers in 2024.

3. Greater use of bags As a result, of the growth of e-commerce, brown packing boxes have become a major tool in our arsenal. We are now seeing consumers becoming more aware of our choices and their impact on the environment.

This – alongside the search for cost savings – is driving a shift towards the use of smaller, more lightweight packaging. In addition, increasingly, boxes are being replaced by bags as the packaging of choice.

Although these bags are made of plastic, they are often both recycled and recyclable, and their flexibility, size, and weight mean greater savings on transport, with the environmental benefits that entails.

As retailers look for cost-cutting options for delivery, we are also seeing multi-use bags becoming more popular, as returns can also be completed using the bag. Then, once the retailer receives that bag back, they put it back into the system for recycling again.

There are lots of advantages to using bags, and this is reflected in their growing popularity as a means of transporting goods, and we may see greater use of these in 2024 as retailers look for more efficient options.

4. Making better use of boxes Of course, bags can’t always do the same job as boxes. Sometimes a standard cardboard box remains the best solution.

However, in the current market companies will be doing all they can to find efficiencies and cut costs.

That includes finding ways to use packaging more efficiently. Ikea does a great job at this – they really use all the space inside a box. This enables to use the smallest-possible box for each product.

Expect more companies to take an Ikea-style approach, finding new ways to make use of every corner of the box, grouping orders, and reducing the size of packaging. This will have a knock-on impact on paper prices and producers.

5. Food and medicines and pharma to stay resilient With the economy teetering on the verge of a recession, and costof-living struggles, there will be a continued impact on sectors such as fast fashion and FMCG, which

will start to impact the packaging sector in 2024.

However, demand will hold up in recession-proof categories. The first is food: we have to eat, and for that, we need packaging; gone are the days when your butcher was allowed to wrap your meat in pages of yesterday’s newspaper.

In fact, the cost-of-living crisis is driving innovation in the sector: when times are tough for many consumers, as we tighten our belts, it drives demand for packaging that preserves our food for longer.

The other sector that will weather economic difficulties is medical and pharma. The pharmaceutical sector is generally resilient during economic downturns, as medicines are so essential. Medical packaging is impressively high-tech: today’s blister packs are designed to maintain the right level of atmospheric pressure to protect each tablet until it’s consumed. *James Burgess is commercial head at Atradius UK, which is part of Atradius, a global provider of credit insurance, surety and collection services, with a strategic presence in more than 50 countries. Atradius is a member of Grupo Catalana Occidente, one of the largest insurers in Spain and one of the largest credit insurers in the world.

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The pulp and paper industries play a key role in the transition and transformation towards a fossil-fuel free circular bioeconomy. By developing circular operations to eliminate unused side streams, and creating new value-added bio-based products, it can be the global leader in zero emissions and zero waste industrial processes.

CircleToZero brings together the continuous development and improvement of existing ANDRITZ technology solutions to achieve this leadership position with clear environmental and financial benefits.

Our shared journey towards zero emissions and zero waste has already started.

ANDRITZ AG ⁄ Stattegger Strasse 18 ⁄ 8045 Graz ⁄ Austria ⁄ andritz.com

22 GREEN PACKAGING NEWS

Pulp Paper & Logistics

Pringles tube ‘designed for recycling’ in relaunch

T

he iconic Pringles cardboard tubular packaging has been revised in Europe to make it easier to recycle.

In a collaborative project between snack giant Kellanova Europe, better known as Kellogg’s, and packaging manufacturer Sonoco, the tinplate bottom of the pack has been replaced with fibre-based material.

Kellanova Europe’s engineering and R&D teams in Belgium have launched the ‘designed for recycling’ Pringles tube and introduced new paper-sealing technology on production lines at Kellanova’s Mechelen plant.

Once fully operational across all production lines, Kellanova will be able to produce more than one billion of the new-type Pringles tubes per year.

The original Pringles tube, according to Kellanova, has been a defining feature of the product since it was launched in the US

by Procter & Gamble in 1968.

Kellogg’s acquired the brand in 2012 for US$2.67 billion.

Consumers are able reclose the tubes with a recyclable plastic lid to ensure the chips stay fresh after opening.

Most importantly, says Sonoco, the new paper-based tube takes into account ‘Circularity

by Design’ guidelines from the European fibre-based packaging value chain, the 4evergreen alliance, with more than 100 members, and obtains a good recyclability score for its suitability for recycling in standard paper mills under 4evergreen’s Recyclability Evaluation Protocol.

January/February 2024

The new Pringles packaging is all cardboard based, making it easier to recycle The tubes are accepted in recycling streams across Europe, as the new paper end makes it easier to recycle.

The launch follows Kellanova’s trial of a steel can in Italy in 2019 and a paper tube in the UK in 2020. The vast majority of the paper used for the old and new tube is made from recycled material, helping to boost the circular economy for recycled paper packaging.

Tracy Murphy, senior director of salty snacks at Kellanova, commented: “As part of our Better Days Promise, we have been working hard to reduce our environmental footprint. The

recyclable Pringles tube is another important step on our sustainable packaging journey. From the trial of the paper tube that we did in 2020, we already know that consumers love the new-look tube, so we’re now very excited that they’ll be able to get their hands on it.”

Seàn Cairns, president of global rigid paper and closures at Sonoco, worked with both companies’ technical teams, to develop the new ‘designed for recycling’ Pringles tube. He notes that consumers are more aware than ever of how their purchasing behaviours are impacting the environment, as well as the more

sustainable packaging options available to them. “With this in mind,” he said, “it’s important for businesses to stay ahead of the curve by exploring new packaging technologies and materials”.

Highlighting the importance of partnership in packaging design, he added, “It was a pleasure working with Kellanova and we look forward to seeing how the new paper-based Pringles tube is received by the market. We hope the success of this project inspires other companies and brands to convert to more sustainable packaging”.

More information from www. sonoco.com

GREEN PACKAGING NEWS 23

Pulp Paper & Logistics

Two new functional papers for more sustainable packaging

P

aper maker Sappi, which for more than ten years has been producing functional papers with integrated barriers against oxygen, grease, water vapour, mineral oil and aromas, as well as heat-sealing properties, is expanding its portfolio.

Seal Light Gloss and Guard MH offer Sappi’s customers features that are said to be even more customised to specific product requirements. The two new flexible packaging papers are made from renewable raw materials and represent recyclable alternatives to fossil-based packaging to help minimise the use of plastic in the long term.

Specifically, Sappi Seal Light Gloss has a glossy surface to offer ‘outstanding’ printing results, while Guard MH is a barrier paper for food and non-food applications.

Both papers are being produced on a barrier coating line at Sappi’s Alfeld mill in Germany Seal Light Gloss: The oneside coated Seal Light Gloss is claimed to provide excellent heat sealability thanks to a coating on the reverse side. The paper, which is available in grammages of 54

Sustainable barrier packaging for food from Sappi and 74 g/sqm, does not have any barrier properties and can be easily recycled in the paper waste stream.

Over the long term, it is intended to help reduce the use of plastics in secondary packaging (for example, confectionery) or in primary packaging for products not requiring a barrier.

Developed for flexible packaging in the food and non-food sectors, it has a natural look and pleasant feel. With a glossy surface, outstanding printing results can be achieved ensuring a highquality appearance to make an impression at the point of sale.

Guard MH: Guard MH barrier paper offers a wide range of

different applications in the food and non-food markets, and can be disposed of and recycled in the paper waste stream. The paper is available in Natural, Silk and Gloss variants.

Depending on these different surfaces on the top side – from natural matt to high-end glossy – brand owners are able to support the brand image of their product at the point-of-sale.

Both the uncoated Natural Guard MH variant and the one side-coated Silk and Gloss variants have an integrated barrier against water vapour and mineral oil, as well as grease (according to test result KIT 12). While Natural is available in grammages of 60, 70

and 90 g/sqm, the Silk and Gloss variants are available in grammages of 75, 85 and 100 g/sqm.

New barrier coater: In the spring of 2023, Sappi commissioned a new barrier coating machine at its site in Alfeld to produce high-barrier papers for recyclable packaging used for food and nonfood applications. Both Seal Light Gloss and Guard MH are produced on the new barrier coating machine.

René Köhler, director of paper and packaging solutions at Sappi Europe, said: “The topic of sustainability is a hugely important priority for us as a paper manufacturer. With our two new functional papers, we are supporting our customers in their efforts to use paper-based, recyclable alternatives to nonrecyclable packaging.

“In addition to Seal Light Gloss and Guard MH, other papers for special applications are currently being developed that will benefit both consumers and branded goods manufacturers. We will be introducing these to the market soon”.

More information from www. sappi.com

Antalis acquires Portuguese distributor Portuguese company 100 Metros, a leader in the distribution of packaging and converting of packaging materials and components, has been acquired by Antalis.

With sales of €13 million and 80 employees, 100 Metros is based in Pacos Ferreira in the Porto

region, and Lisbon.

Founded in 2000, 100 Metros specialises in the design of customised and bespoke industrial packaging.

Cardboard, film, foam and bubble transformation are key elements of the company’s business, which also boasts an in-house

personalisation activity using its own machinery, which accounts for a sizeable proportion of sales.

For more than 20 years, the company has been developing specific expertise in several sectors, particularly for the automotive and ceramics industries.

Antalis, already well-established in Europe, continues to expand its presence in the packaging market in Iberia adding 100 Metros to its recent acquisitions of Cohal, Garalmi and Gosuma in Spain.

More information from www. antalis.com January/February 2024

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Japanese version of ‘Packaging Design for Recycling Guide’ launched

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roduced by the World Packaging Organisation (WPO), the ‘Packaging Design for Recycling Guide’ has recently been translated into Japanese. This is the 11th translation in addition to the versions in English, German, Spanish, Arabic, Portuguese, Thai, Latvian, Czech, Hungarian and Georgian.

Developed by WPO, Circular Analytics, FH Campus University of Applied Sciences and ECR Community, the Guide is a starting point to understand best practice examples, using stateof-the-art technology that can be applied and tailored to suit the recovery and recyclability capabilities and infrastructure on a regional and local level.

The Japanese version was launched at the WPO Board Meeting in South Africa in

November, which was attended by former president, Pierre Pienaar, current president, Luciana Pellegrino, representative of Japan Packaging Institute (JPI) Hiroko Akieda, and vice-president of Sustainability & Save Food, Nerida Kelton.

Pellegrino commented: “The ‘Packaging Design for Recycling Guide’ is a very important tool for the global packaging community to ensure that our industry is taking steady steps, based on scientific foundations, to achieve a circular economy model. It contributes to address the challenges that face the world in terms of climate change, environment and preservation of natural resources.

“We highly recommend the industry to explore this Guide in a way of driving efforts based on a common voice of the packaging

industry in terms of recycling and circular economy”.

Managing director of JPI, Yoichi Sonoyama is proud of the translation as a part of its own 60th anniversary celebrations.

“It is apt that JPI have finalised the Japanese translation in our 60th year, especially because WPO was established in Japan in 1968,” said Sonoyama-san. “We also wanted to play our role in ensuring that our industry has access to the latest resources, training and guides. By delivering better packaging design to everyone, we will be able to provide better packaging around the world. This design guide will help to aid this objective.”

Says Nerida Kelton: “The work undertaken to translate the Global Packaging Recycling Guide should not be underestimated and a huge acknowledgement

must go to Yasuhiko Ide, Toshio Arita and Mitsuhiro Sumimoto from JPI, who were dedicated to complete the translation by the second WPO Board Meeting for 2023.

“These translations are no small feat and require experts in technical packaging terminology to be able to accurately formulate the translation. The Japanese translation is now available to download and access for free via the World Packaging Organisation website and we are looking forward to launching even more guides in 2024. The goal is to ensure that every country in the world has access to the guide so that we can design our waste at the start and ensure that packaging is recycle ready,” said Kelton.

More information from www. worldpackaging.org

Packaging papers for home composting UPM Specialty Papers has launched a range of packaging papers that are designed for home composting. Six UPM packaging papers are now certified as home compostable, meeting the NFT51-800:2015 standard.

All certified as industrially compostable (EN13432:2000), in barrier papers UPM offers Prego and AsendoT; in coated one-side (C1S) papers it offers FlexPack, UniquePack and UniquePack Strong; and in speciality kraft papers it offers Solide Lucent.

These fibre-based and recyclable packaging materials enable brand owners and converters to develop home January/February 2024

UPM’s compostable papers being used for fast food packaging compostable packaging. Susanna Hyrkäs, senior manager for sustainability at UPM Specialty Papers, said: “Recycling should always be the first option to

consider when possible. However, compostability is a good option when recycling of packaging papers is not possible due to food residues, for example.

Compostability can also play a role when recycling infrastructure is limited.”

Compostability is a form of recycling that degrades materials into fertile soil suitable for plant growth. The differences between home composting and industrial composting are found in the process temperature and the time it takes before disintegration and biodegradation is expected.

Given the right conditions (2030 deg C), home compostable materials are designed to biodegrade within 12 months and disintegrate within six months into non-ecotoxic compost.

More information from www. upmspecialtypapers.com

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PA Consulting acquires the first Scala machine

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einforcing its position in sustainable packaging, PA Consulting, a global leader in innovation and transformation consulting, has acquired the first PulPac Scala production line, which uses Dry Moulded Fibre technology.

Tony Perrotta, a partner in sustainability and the regenerative economy at PA Consulting, was excited about the new platform, saying: “By acquiring a PulPac Scala machine, we are taking another step in bringing sustainable Dry Moulded Fibre packaging to life. The production line is now fully commissioned on site at Cambridge in the UK, and will enable us to better serve

global brands with end-to-end production capabilities – from feasibility to market launch volumes”.

The PulPac Scala machine boasts new capabilities, enabling the formation of high-quality, customisable packaging with high output tailored to the rigorous needs of sustainable packaging. Building on existing injection moulding components adapted for Dry Moulded Fibre, Scala provides specifications that promise to redefine packaging with the focus on circularity’.

Sanna Fager, commercial chief at PulPac, welcomed PA Consulting’s acquisition and said: “We’re thrilled to see PA Consulting embrace the PulPac Scala machine as a launch partner.

The PulPac Scala machine platform ordered by PA Consulting Our close-knit partnership has been instrumental in driving sustainable packaging forward across leading global brands.

“PA’s commitment to innovative solutions and leveraging technology is a testament to our shared vision for a more sustainable future. This will

increase the ability for our customers to drive brand value while also minimising environmental footprint with reductions of up to 80 percent compared to conventional technologies”.

More information from www. paconsulting.com

Smurfit Kappa’s Design2Market Factory to expand in Europe Smurfit Kappa’s Design2Market Factory will be expanding across Europe after a successful first year in operation. The facility, which enables customers to test and adapt their packaging on a small scale before market launch will

This Nestlé pet food pack resulted from development at Smurfit Kappa’s Design2Market Factory

be replicated across Germany, Italy, Poland and the UK. The original 3,000sqm innovation hub in the Netherlands has been home to more than 50 projects for some of the world’s biggest consumer brands. Smurfit

Kappa’s multi-disciplinary team takes a packaging challenge and designs a new package which is ready to be tested in the market in just two weeks.

In addition to reducing risk and turnaround time, Design2Market Factory is said to provide customers with sustainable packaging that reduces their carbon footprint and supports their recyclability targets.

So far, the team has created, analysed and launched many new designs including shelfready packaging for detergent, a paper-based replacement for shrink wrap and a complete range of eCommerce packaging.

Design2Market Factory also creates packaging that meets

Amazon’s certification standards.

Arco Berkenbosch, Smurfit Kappa’s chief innovation officer, said: “We are thrilled to have reached this milestone. The journey of the Design2Market Factory has been remarkable and the trust placed in us by many industry-leading household names is testament to our commitment to innovation and excellence at speed.

“Broadening our European footprint will help more customers to stand out in an increasingly competitive landscape and achieve their sustainability goals in line with our Better Planet Packaging initiative.”

More information from www. smurfitkappa.com January/February 2024

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Mondi leads the change on white goods EPS packaging

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aper maker Mondi has launched a range of corrugated packaging products that replace Expanded PolyStyrene (EPS), which is widely recognised as a significant contributor to marine plastic pollution, making up more than 40 percent of plastic debris on Asian beaches, and it has listed a number of sources to support the move (ref 1).

Bans on EPS packaging have gained tremendous momentum recently, particularly in the European Union and the wider Caribbean region (ref 2,3).

Legislation banning the use of EPS packaging has also been introduced in Fiji, the Philippines and some regions of the United States, just to name a few (ref 4,5,6).

With the ongoing development of the United Nations Treaty on Plastic Pollution, governments from more than 170 nations are working toward policy measures to combat the negative environmental impacts of hard-torecycle plastics. The introduction of bans, levies and increased disposal fees for EPS packaging materials will continue to be on trend for the foreseeable future, especially in regions lacking recycling infrastructure.

A sustainable alternative Fibre-based corrugated packaging is 100 percent recyclable and 100 percent compostable, making it the ideal packaging material.

What’s more, says Mondi, its corrugated packaging includes a wide portfolio of corrugated boxes made of recycled fibres.

January/February 2024

Paper-based packaging boasts an impressive 82.5 percent recycling rate in Europe, outperforming the combined recycling rates of all other packaging materials (ref 7).

The recycling value of corrugated packaging has enormous potential worldwide. Paper fibre can be recycled with good quality many times, keeping fibres in circulation (ref 8,9).

As a partner for sustainable growth, Mondi material and design experts are developing high-performance, corrugated solutions to enable a shift toward circular packaging for white goods and electronic equipment. Industries have long relied on crumble-prone EPS material to protect valuable goods. Until now, replacing EPS materials with paper-based solutions was prohibitive from a cost perspective, but extended producer responsibility mandates like those under the EU Packaging and Packaging Waste Directive (PPWD) have transformed economic factors (ref 10).

Corrugated solutions Mondi says there is no silver bullet when it comes to white goods and electronic packaging – EPS can chip or break during transport, resulting in costly product damage and returns.

When designing Snug&Strong corrugated packaging, Mondi says it gathered a team of experts to collaborate with customers to understand their production line and packaging requirements.

Whether developing a recyclable, multi-material packaging concept or creating a plan to gradually

Mondi is targeting EPS for white goods with its new Snug&Strong corrugated packing replace EPS components over an extended period, it is possible to find sustainable and viable solutions through collaboration.

By setting out to replace EPS materials in packaging, manufacturers have a unique opportunity when partnering with Mondi to create fully recyclable packaging solutions while also optimising and automating their packaging processes. Fit-for-purpose recyclable packaging satisfies consumer demands for sustainability and fulfils upcoming legislative requirements.

the component solution easier to handle and less expensive to store and transport.

It is not always easy to strike a good balance between protection, cost and sustainability when it comes to packaging. Mondi’s Snug&Strong corrugated packing, however, is a cost-efficient and viable alternative to EPS when considering the total cost of ownership.

More information from www. mondigroup.com/products-andsolutions/replacing-expandedpolystyrene-in-white-goodspackaging/

Protection, cost and sustainability

References 1. Hamsun H.S. Chan, Christelle Not. (2023) Variations in the spatial distribution of expanded polystyrene marine debris: Are Asian coastlines more affected? Retrieved from: www. sciencedirect.com/science/ article/pii/S2666765723000029.

2. Directive (EU) 2019/904. The reduction of the impact of certain plastic products on the environment. European Parliament, Council of the European Union. Retrieved

Mondi’s Snug&Strong corrugated packaging can do more: ease supply chain complexity; improve packaging processes; and help brands be more environmentallyfriendly. The custom-fit, 100 percent paper-based industrial packaging offers excellent protection for white goods and electronic equipment. In addition, Snug&Strong is delivered flat and requires less space than traditional EPS packaging, making

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from: www.eur-lex.europa.eu/ eli/dir/2019/904/oj.

3. UNEP. Report on the Status of Styrofoam and Plastic Bag Bans in the Wider Caribbean.

Retrieved from: www.unep.org/ cep/resources/report/reportstatus-styrofoam-and-plasticbag-bans-wider-caribbean.

4. Chaudhary, Felix. (2021) Ban on polystyrene to start next month.

Retrieved from: www.fijitimes. com/ban-on-polystyrene-tostart-next-month/.

5. Parkinson, Lindey. (2021) Philippines House passes Singleuse Plastic Products Regulation Act. Retrieved from: www. foodpackagingforum.org/news/ philippines-house-passes-singleuse-plastic-products-regulationact.

6. McCarthy, Joe. (2017) States declare war on Styrofoam.

Retrieved from: www.cbsnews. com/news/styrofoam-banstates-declare-war-peoplethink-it-breaks-down/.

7. Eurostat 2023. Retrieved from: www.ec.europa.eu/eurostat/ databrowser/view/cei_wm020/ default/table?lang=en.

8. CEPI (2022) Cepi position paper on the revision of the Packaging and Packaging Waste Directive.

Retrieved from: www.cepi.org/ wp-content/uploads/2022/10/ PPCG-MG-22-030_Cepiposition-paper.pdf.

9. European Paper Recycling Council. Monitoring Report 2022. Retrieved from: www. cepi.org/wp-content/ uploads/2023/09/EPRCMonitoring-Report-2022_Final. pdf.

10. Directive 94/62/EC. Packaging and packaging waste. European Parliament, Council of the European Union. Retrieved from: www.eur-lex.europa.eu/ legal-content/EN/TXT/?uri=CEL EX:01994L0062-20150526.

Colourful partnership creates high-quality packaging

Koehler Paper and Ebro Color are collaborating to create a range of high-quality packaging.

Koehler’s Greiz mill in Germany offers high-quality recycled paper made from 100 percent secondary fibre while Ebro Color produces high-quality product packaging and gift boxes using paper supplied by Koehler Paper.

The partnership is said to take advantage of the synergies in the packaging industry and the importance of high-quality colourful card packaging for product presentation. In a world where packaging has a significant influence on the overall impression of a product, Koehler Paper and Ebro Color have entered into a partnership based on trust and driven by quality and originality, say the companies.

Koehler recycled paper boasts the Blue Angel and EU ecolabels, and offers a high quality and natural feel. Koehler says it is is a sustainable alternative for use in product packaging, with no compromises made in terms of quality, reliability or appearance.

Christoph Braun, sales manager at Koehler Paper, commented: “There is a clear trend when it comes to packaging material options. Paper scores points right across the board and is becoming an increasingly important factor in consumer decisions.” The recycled paper can be disposed of as waste after use.

Ebro Color specialises in German-made product packaging and particularly high-quality folding boxes for consumer goods. Along with product and gift packaging for brands, OEMs, packaging companies and printers, Ebro Color produces Buntbox gift boxes from creative board. The Buntbox gift box was designed specifically for the stationary trade and has its own sales and display concept.

The collaboration between the companies is said to be an impressive demonstration of the potential synergies in the packaging industry. Koehler Paper supplies high-quality coloured card in a variety of colours and qualities.

Ebro Color uses this high-

Buntbox gift boxes from Ebro Color made from Koehler Paper’s high-quality coloured, recycled paper quality recycled paper to produce its packaging. As well as being functional, Ebro Color’s colourful and environmentallyfriendly packaging is aesthetically pleasing and ensures that its customers’ products are presented in the best light.

Ebro Color says its coloured cardboard boxes are “a cut above the conventional boxes seen on shelves”. While just the surfaces of conventional boxes are printed, Ebro Color offers boxes that are completely dyed.

Simon Brodbeck, managing director of Ebro Color, says: “Ebro Color is known for delivering high-quality, colourful, sustainable packaging solutions that catch customers’ attention.

The partnership with Koehler Paper demonstrates how highquality, coloured recycled paper can enrich the packaging industry and improve the customer experience.”

More information from www. koehler.com January/February 2024

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Pro Carton Awards invites young designers and students

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ntries are being invited for the 2024 Pro Carton Young Designers Award (PCYDA) and Pro Carton Student Video Award (PCSVA).

Helping to promote sustainable packaging innovation across Europe, the PCYDA and the PCSVA celebrate the up-andcoming talents across sustainable packaging design and filmmaking.

Both competitions, which are free to enter, encourage students to learn about the packaging industry, whilst simultaneously offering them the chance to enhance their creative skills.

The Pro Carton Young Designers Award continues to be a prestigious platform for talented young designers to showcase their skills and make their mark in the sustainable packaging industry.

Offering students the chance

Creative design is being encouraged with entries to the Pro Carton Young Designers Awards to pioneer and showcase their innovative ideas, the award has three categories: Creative Cartonboard Packaging – Food & Drink; Creative Cartonboard Packaging – All Other; and the Sustainability Award.

This competition provides students with the opportunity to gain experience outside the classroom, build networks, create job opportunities and win

exciting prizes.

The Pro Carton Student Video Award invites young aspiring videographers to produce videos that highlight the versatility, sustainability and innovation of cartonboard packaging. This award allows students to explain the benefits of cartonboard in everyday life in a captivating way, with the best entries being congratulated with cash prizes.

Director of marketing & communications at Pero Carton Winfried Muehling, commented: “Both the Pro Carton Young Designers Award and the Pro Carton Student Video Award offer a fantastic opportunity for the future generation of packaging enthusiasts to showcase their talent and, of course, the versatility of cartonboard.

“We will further extend the learning opportunity to allow the students a professional sales pitch of their respective projects. It is at the same time an opportunity for the industry to demonstrate exciting job opportunities for young graduates. We look forward to once again celebrating the creative and inspiring entries that are submitted for 2024.”

More information from www. procarton.com/awards/

Mondi hosts round table on construction bags Industry leaders were brought together by Mondi in Madrid in November 2023 for an expert round table to discuss how to improve the circularity of used paper bags in the construction industry.

The event studied at how to build systems that will prevent the disposal of used paper bags, working towards implementing

a process of efficient collection, sorting and recycling that can be managed on an industrial scale.

Partners attending were representatives from the value chain and included Mondi, Envalora, Neinor Homes, OHLA, Arpada, Macotran, RCD Asociacion, S Solís, Uder, Alier, Saint-Gobain and CoCircular. The industry leaders share a vision of

Industry leaders met in November to discuss industrial bag recycling January/February 2024

boosting the circularity of paper bags used in the construction industry and see collaboration and stakeholder dialogue as a critical activity to achieve this.

The event followed a successful pilot project driven by Mondi, which set up a collection and recycling system for used paper bags in Spain. The project was initiated because paper bags used in the construction industry are currently not recycled at scale, resulting in valuable fibres being lost.

In this pilot, various construction companies and specialised collectors for construction and demolition waste teamed up to manage the collection of used paper bags at

construction sites, transportation and the reprocessing of the used paper bags. This pilot provided a proof of concept to increase the circularity of used paper bags.

Carlos Martinez Ezquerra, circular economy manager for flexible packaging at Mondi, said: “Improving the circularity of used paper bags in this industry is vital and our successful Spanish pilot project shows that it can become reality, but Mondi cannot do it alone.

We need committed partners at every stage of the value chain to collaborate closely and create a successful model that can close the loop.”

More information from www. mondigroup.com

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Multiple awards for Smurfit Kappa

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aper products manufacturer Smurfit Kappa has won a number of awards in the Americas for innovation and expertise in supply chain efficiency and design excellence, along with an impressive 12 gongs in the WorldStar global packaging award.

The UK-based paper maker was honoured with the 2023 Strategic Supplier Innovation Award from the Chamberlain Group (CG), in recognition of its efforts to improve supply chain efficiency through ground-breaking technologies and sustainable packaging solutions.

Smurfit Kappa also achieved success at the 42nd Convention of the Association of Caribbean, Central and South American Corrugators (ACCCSA), in the Design and Booth Competition with five awards. One of the designs was for the eco-conscious fashion brand Guadalupe Design which specified a sustainable eCommerce pack that would convey the beauty of its products.

The WorldStar winning fibre-based designs included an octagonal cake box, a transportation pack for electric scooters and a striking point-ofsale display for sardines.

Smurfit Kappa shone in the e-commerce category. One of the products was a clever pack for plants that keeps the soil and pot separate to prevent spillage and arrive intact.

The paper maker’s sustainability credentials were evident such as with a 100 percent paper-based reel for engineering components, previously made from plastic and

Smurfit Kappa’s award-winning sustainable box for Guadalupe Design metal, which replaces 35 tonnes of plastic a year.

In the Household category, a Bag-in-Box for paint maker PPG replaced a plastic can. This facilitated easier pouring of the

paint and reduced plastic use by 80 percent.

Commenting on Smurfit Kappa’s success in the WorldStars, Arco Berkenbosch, chief innovation officer at Smurfit Kappa, said:

“We are thrilled to have come out top at these highly respected and global awards. Over the years, we have built up a collection of over 8,000 designs on our Innobook tool, which our design teams can draw on for inspiration. This has really helped to foster a culture of creativity and raise the bar internally.

“I’d like to congratulate the talented people across Europe and the Americas that came up with these award-winning solutions. All of them solved a particular problem for the customer in a truly unique way and delivered considerable sustainability benefits.”

More information from www. smurfitkappa.com Smurfit Kappa’s award-winning point-of-sale display for Lindt chocolate January/February 2024

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Corrugated cutting with higher speed and precision

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imed at corrugated converters, what is described as a ‘game-changing’ digital cutting platform has been launched by Kongsberg Precision Cutting Systems, based at Gent in Belgium.

Kongsberg Ultimate is said to deliver unprecedented levels of productivity, precision and safety during high-speed cutting operations.

Specially-designed drive technology provides an acceleration rate of up to 2.74G and a cutting speed of 168 metres per minute.

“Engineered with our deep understanding of corrugated and display converters’ needs for precision, the Kongsberg Ultimate promises to redefine standards and usher in a new era

The Kongsberg Ultimate features a carbon-fibre beam and a tool head camera of productivity and innovation, delivering a fast return on investment for convertors of corrugated board,” said Kongsberg PCS chief executive, Stuart Fox. “Enhancing operations and providing a significant competitive advantage, the platform sets a new industry benchmark and is set to drive the future of corrugated production for years to come.

“Kongsberg Ultimate directly addresses the challenges faced by

corrugated converters involved in continuous high volume multibatch production,” says Fox. “With corrugated converters around the world under increasing pressure to produce better, faster, safer and more efficiently to meet the demands of the global market, we have underlined our commitment to deliver a solution that has been engineered for precision and built for productivity,” added Fox. “Businesses seeking

to elevate their operations need look no further than the Kongsberg Ultimate.”

Key features include a carbonfibre beam that is capable of applying a 50kg downforce, and a tool head camera that ensures every cut aligns perfectly. Selfdiagnostics and remote operator alerts deliver high utilisation.

Fox said: “We have worked creatively to ensure that our future is built upon manufacturing equipment that our customers and team can be proud of. The Kongsberg Ultimate is not just an evolution but a leap forward in corrugated production technology and a commitment to the corrugated industry for the future.”

More information from www. kongsbergsystems.com/en/ cutting-systems/tables/ultimate/ overview

Flexible paper pallet wrap that replaces plastic film An updated flexible paper wrap that replaces plastic stretch film has been launched by Mondi.

Recyclable and said to offer more efficient logistics, Advantage StretchWrap has been developed

by Mondi to stretch and resist puncturing, making it ideal for replacing the film that has traditionally been used for pallet wrapping and transportation.

Advantage StretchWrap has 62 percent lower greenhouse gas (GHG) emissions when compared to virgin plastic stretch film, and 49 percent lower GHG emissions when compared to plastic film made with 50 percent recycled content, according to a peerreviewed independent life cycle assessment.* First to take up the new product is paper bag manufacturer January/February 2024

Advantage StretchWrap has a claimed 62 percent lower greenhouse gas (GHG) emissions when compared to virgin plastic stretch film Sentrex. By switching to Mondi’s kraft paper and using EW Technology’s automated wrapping systems, Sentrex was able to increase efficiency in the

wrapping process: The production of the paper bags requires a drying process to remove moisture from them before being wrapped in plastic stretch film, to avoid condensation within the packaging. Advantage StretchWrap is breathable and is suitable to wrap and pack products immediately after paper bag production within one in-line process.

The larger dimensions of the Advantage StretchWrap reel mean that a new reel is only needed every 400-600 pallets compared to every 40-60 pallets for plastic wrapping. The paper can be used to wrap a variety of shapes and sizes of pallets and cover the gap between the pallet and the product, providing good stability and safety during

transportation.

Jan Murzyn, business development manager for speciality kraft & functional Paper at Mondi, says: “This change means that Sentrex can wrap their products in more sustainable packaging, work towards a more circular system and make a positive contribution to the environment.

The collaboration with Sentrex is living proof that our Advantage StretchWrap solution is not limited to business-to-consumer applications but brings value to leading industry players in the business-to-business sector.” * www.mondigroup.com/ news-and-insight/2021/life-cycleassessment-of-mondis-paper-forpallet-wrapping-shows-lowerclimate-impact/

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Industrial applications are future proofed with latest ABB Ability field information manager

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nhanced operational efficiency in pulp and paper mills is said to be ensured with the latest version of ABB’s Ability Field Information Manager (FIM 3.0).

The digital software enables faster, more intuitive configuration, commissioning, diagnostics and maintenance of devices.

Providing better performance and diagnostic data collection from of fleets of devices, the latest version of FIM 3.0 makes better use of OPC UA and PADIM to transport data from field devices to cloud-based condition-monitoring systems.

ABB says that In doing so it helps customers achieve smarter maintenance and enhances their engineering efficiency. New asset management capabilities which include increased device

ABB Ability Field Information Manager empowers businesses to embrace digital transformation, ensuring flexibility, efficiency, and competitiveness across fleets of devices condition monitoring are also said to pave the way to predictive maintenance.

“In the era of Industry 4.0, ABB Ability Field Information Manager empowers businesses to embrace digital transformation, ensuring flexibility, efficiency, and

competitiveness across their fleet of devices,” said Stefan Basenach, head of process control platform at ABB. “With its future-proof capabilities, it helps customers enhance operational efficiency while remaining relevant as industry standards evolve.”

ABB’s enhanced FIM 3.0 software serves as the bridge between IT and OT to enable datadriven decision making. Offering a wider range of connectivity options for ASi-5, PROFINET, PROFIBUS, HART IP, and HART, FIM 3.0 fits into any existing system landscape for increased plant agility. Strengthened EthernetAPL support also ensures market relevance well into the future.

ABB’s Ability Edgenius Operations Data Manager further extends FIM 3.0 capabilities by enabling the collection and management of data from OPC UA, making valuable information accessible for edge and cloud-based applications, as well as offering advanced fleet management capabilities, simplifying the monitoring and maintenance of field devices across multiple locations.

Tissue product packaging with less waste With the South American tissue market expected to grow at a yearly rate of 4.6 percent between 2020 and 2028*, Italian equipment manufacturer Microline is promoting its wrapping system for a range of folded tissue products.

Eco-Wrap is aimed at both small and medium-sized enterprises that intend to automate the end-of-the-line with a high-tech process along with meeting the needs of multinationals with medium-to low-speed automated lines.

The machine is designed for wrapping ‘AFH’ rolls or folded products using plastic film and

Eco-wrap: tissue product packing with less waste is able to use a wide range of packaging materials. The machine creates completely

sealed bags, allowing a broad series of product configurations.

This type of packaging is

especially well-suited to pre-packaged paper rolls for industrial use and individually packed folded products. The packaging process does not generate any wrapping material scraps or rejects, which cuts out disposal costs.

Eco-Wrap also saves energy by forming bags that are tight-fitting and do not necessarily require the use of a shrink tunnel. Lastly, the one-piece design allows fast commissioning of the machine, which can be quickly installed. * https://www. databridgemarketresearch.com/ reports/south-america-tissuepaper-market January/February 2024

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Successful start-up of Asia Symbol’s BM13 at Rugao mill

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eading Chinese pulp and paper maker Asia Symbol had its new BM13 machine at the Rugao mill, north of Shanghai, started up by Voith at the end of October 2023.

The machine has a width of 8.16 metres and with a design speed of 1,400 metres per minute produces mostly high-quality white folding boxboard in the basis weight range of 170 to 400 gsm with an annual capacity of around one million tons.

“Voith has always been a reliable partner for us,” says Eric Xu, general manager of the new line at Asia Symbol. “Thanks to Voith’s full-line package, the Rugao BM13 achieves excellent results in terms of product quality, production efficiency, and operating and maintenance costs, which further strengthens our competitive

Asia Symbol’s new million-ton-a-year board machine at the Rugao mill in China advantage in the market.”

The full-line service provided

by Voith includes a wide range of systems, from BlueLine stock preparation and the XcelLine paper machine to two VariFlex Performance winders with a fully automated Flying Splice reel change.

For the plant, the focus is on sustainable and efficient systems.

Installed along with the Triple NipcoFlex press, is an EcoHood dryer hood, ropeless transfer in the dryer section and contactless qDry Pro drying on which HelioX infrared emitters. Voith also supplied a comprehensive wear parts package and automation, including OnControl MCS, DCS, Drive Control, OnQuality MD/CD Control and and OnCare Health

High-performance rewinder for Jiangxi Five Star Paper Jiangxi Five Star Paper has ordered a high-performance rewinder from Italy’s A.Celli for installation at its Jiujiang mill in Jiangxi province, China.

The E-Wind P100 rewinder will be used for processing decorative base paper in the range from 50 to 120gsm and be capable of handling rolls in widths up to 3.9 metres at speeds up to 2,000 metres per minute.

Mr Zhang, vice general manager of Five Star Paper, said: “In the world of winding and rewinding machinery, A.Celli is synonymous with quality and reliability. We are January/February 2024

A.Celli is supplying a rewinder to Jiangxi Five Star Paper in China very pleased to be working with this great made-in-Italy company, and we are confident that the P100 rewinder will be up to the task.”

Privately-owned and founded in 2015, Jiangxi Five Star Paper Co is part of Quzhou Wuzhou Special Paper, one of China’s largest food wrapping paper producers.

condition monitoring system.

Voith says the commissioning of Rugao BM13 strengthens Asia Symbol’s market position and reinforces its supply chain. The line supports the paper maker’s goal of reducing carbon dioxide emissions from paper production and promoting the joint development of local upstream and downstream industries. The start-up is said to have laid a solid foundation for future cooperation and development between the two companies, which aim to further deepen their collaboration in the fields of technological innovation and sustainable development.

Part of the RGE Group, Asia Symbol makes BHKP, NBKP, DP, liquid packaging board, high grade ivory board and uncoated woodfree printing and office paper for domestic and overseas markets.

In brief l Brazilian pulp producer Suzano has selected Andritz to provide modular maintenance services for its new mill being built in Ribas do Rio Pardo in the state of Mato Grosso do Sul, Brazil. The five-year contract covers several maintenance modules for all process islands and equipment of the new mill, which is scheduled to start up by June 2024. With an annual production capacity of 2.55 million tons, the new Suzano mill is expected to be the world’s largest plant with a single eucalyptus production line. Andritz is supplying the main equipment and services for the project.

Stop collecting paper samples!

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34 PROJECTS & CONTRACTS

Pulp Paper & Logistics

World’s largest mechanical pulping line started up in China

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hat is claimed to be the world’s largest mechanical pulping line for printing and writing paper has been started up by Shandong Huatai Paper at its Dongying mill in the Shandong Province of China.

Rebuilt by Andritz, the pulping line’s capacity has been increased from 100,000 to 300,000 tons per year while cutting energy consumption and raising quality and yield.

Commenting on the start-up, Wei Lijun, director of Shandong Huatai Paper, says: “Thanks to the close cooperation between the teams of Andritz and Shandong Huatai, we were able to start up the rebuilt line as scheduled.

We are delighted about the

Shandong Huatai Paper’s newly rebuilt mechanical pulping line is said to be the world’s largest with a capacity of 300,000 tons a year massive increase in capacity as well as the additional benefits of the modernisation. Energy consumption has dropped by about 15 percent and pulp quality has greatly improved. The amount of fibre shives has also gone down significantly. As a result, we are able to cut back on imported chemi-mechanical pulp in our

raw material structure, which lowers costs and supports our environmental performance.”

Andritz rebuilt the two highconsistency (HC) refiners and the screw presses, disc filters, and screens, and supplied new equipment for other process steps.

The line now features the following new technological highlights:

a PrimeMSD Impressafiner for optimum wood chip maceration and chemical impregnation; a Side-Entry Plug Feeder (SEPF) feeding system; and an Hydraulic Commander to improve the HC refiners’ operability and supply top quality fibre with lower energy consumption Andritz also provided the basic engineering and supervised the mechanical installation, commissioning, and start-up.

Shandong Huatai Paper Industry Shareholding is part of the listed Huatai Group, regarded as the world’s largest producer of newsprint and China’s largest producer in the chlor-alkali industry. The Huatai Group each year produces three million tons of paper and board as well as two million tons of chemicals.

OCC line ordered by Papel Prensa for Buenos Aires mill Papel Prensa SA has ordered a complete old corrugated container (OCC) line from Andritz for its Buenos Aires mill in Argentina for start-up this year.

Initially the line, which will include a reject handling system, will be able to daily process 180 tons of locally sourced OCC. Processing capacity will be easily increased, says Andritz, with minor adjustments to the configuration to support the expected rise in pulp demand for the production of corrugated paper.

Diego Colabardini, chief executive of Papel Prensa, says: “Our goal is to produce top-quality paper January/February 2024

while reducing our environmental footprint through the efficient use of energy and natural resources, based on our strategy of promoting circular economy in a sustainable business. Andritz’s advanced technology and extensive experience in pulping will help us achieve this goal.”

Scope of the project comprises: a complete LC pulping system with a FibreSolve FSR pulper and a detrashing system to ensure slushing of the raw material at minimum fibre loss; a protection cleaning, fractionation and screening stage including a PrimeScreen X with newlydeveloped PrimeRotor for high

This Andritz PrimeScreen X will be part of the screening process in the new OCC line ordered by Papel Prensa screening efficiency at lower power consumption; a reject handling system featuring a Reject Compactor to dewater the

rejects to the highest possible dry content; and erection supervision, commissioning, start-up, and training.

PROJECTS & CONTRACTS 35

Pulp Paper & Logistics

ABB automation and drives for Gascogne’s new MG paper machine

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s part of the installation of what will be the world’s largest uncoated machine-glazed paper machine at Gascogne Papier’s Mimizan kraft pulp and paper mill in France, ABB is to supply a complete automation and drive system.

Replacing three older machines, the mill’s new PM7 – a PrimeLine MG being supplied by Andritz (see PPL July-August 2023) – will be fully integrated and standardised using the ABB’s Ability System 800xA distributed control system (DCS), and an ABB Quality Control System (QCS) for pulp and paper, drives and motors.

Advanced QCS controls will enable automatic grade changes and multivariable cross-direction.

The systems include 8000 I/O, ACS880 multi-drives and ABB’s SynRM IE5 motors. ABB says that the package will help Gascogne Papier save on energy costs

Automation and drives are being supplied by ABB for Gascogne Papier’s new PM7 while simultaneously reducing waste by making more on-spec paper.

The new paper machine will have a web width of 6.8 metres and with a design speed of 1,300 metres per minute will be capable of yearly producing 125,000 tons of paper in basis weights between 25 and 120 grams per square metre, setting a new industry benchmark for uncoated MG papers.

“We have an established

relationship with Gascogne and are delighted to continue supporting them in their mill production goals,” said Pamela Murphy, European operations manager for pulp and paper at ABB. “The project also underscores our important collaboration and the complementary technology and expertise that we will bring to Gascogne.”

ABB says that IE5 ultra-premium SynRM motors are the same size

Zhejiang Jingxing successfully starts up deinking line Zhejiang Jingxing Paper has successfully started up a deinking pulp (DIP) line supplied

by Andritz to its Pinghu mill in the Zhejiang Province of China.

The line processes a mix of office waste and old books with a capacity of 200 bdt/d to produce de-inked pulp for a range of papers. With three loops for flotation along with de-ashing and double dispersing, the line

enables the highest stock quality to be produced for white top linerboard and other papers.

Li Liubai, vice chief engineer at Zhejiang Jingxing, says: “We already have Andritz tissue machines in operation. The Andritz team’s approach to our most recent project has again been highly professional and supportive. As a result, the start-up went as smoothly

as expected. The new DIP line helps us to improve our endproduct quality and enrich endproduct variety. In addition, our operating costs have decreased remarkably.”

Andritz was responsible for installation of the DIP line, supervision, start-up and training. Key components of the line included: a FiberFlow drum pulper; a PrimeScreen X screen

and output power as commonly used IE2 induction motors but offer up to 50 percent lower energy losses and significantly lower energy consumption.

Additional benefits include lower bearing and winding temperatures for better reliability and long life, and less noise.

Deliveries by ABB started early in 2023, with QCS and drives being supplied to Gascogne during 2024, along with commissioning of the machine. basket for increased screening efficiency with lower power consumption; a PrimeFilter D disc filter to handle high feed consistencies while reducing energy consumption; and a SelectaFlot flotation for dirt removal and brightness with minimum fibre loss.

Founded in 1984, Zhejiang Jingxing Paper is one of China’s leading packaging paper and household tissue producers. The company operates 10 production lines for a broad range of applications.

January/February 2024

36 PROJECTS & CONTRACTS

Pulp Paper & Logistics

Ranheim Paper & Board in Norway orders line upgrade from Toscotec

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ardboard producer Ranheim Paper & Board has ordered the second phase of a technological upgrade to its PM5 line at its mill near Trondheim in Norway.

The order from Toscotec follows the completion on schedule of a dryer section rebuild on PM5 by the Italy-based firm.

PM5 produces greyboard and coreboard in the basis weight range from 220 to 540 gsm.

The PM5 dryer section rebuild had the goal of improving the efficiency of the dryer section by better controlling the felt tensions and felt guiding.

Toscotec also re-designed several felt loops to be internal and thereby improved the machine’s cleanliness.

The second phase will attain the highest felt tension in the dry end. The existing long shaft drive system of PM5 will be upgraded with the application of a socalled silent drive in the dryer section, which involves driving the dryers through the fabric, replacing gear cases and reducing noise. Toscotec will also supply a completely new electrical drive and related control system for the whole paper machine. The service package includes the full erection with supervision,

Øistein Vedahl, managing director of Ranheim Paper & Board (left) shakes on the paper maker’s latest deal with Giancarlo Gianlorenzi, sales manager at Toscotec training, commissioning, and start-up assistance.

China’s largest high-kappa fibreline starts up at Nanning Sun Paper A high-kappa fibreline – the largest of its type in China at 1,600 adt/d – and lime kiln plant has been started up by Andritz at Nanning Sun Paper’s pulp and paper mill in Guangxi Province.

Project director at Nanning Sun Paper Zang Zijia said, “Start-up of the fibreline and lime kiln went very smoothly. The project progressed quickly, the start-up test was completed within one month after feeding, and now the equipment is running stably.

We will definitely continue working with Andritz in the future to further increase our capacity and efficiency.”

The project comprised: l The hardwood line including a chip feeding system, continuous January/February 2024

The staff at Nanning Sun Paper mark the start-up of the new high kappa fibreline cooking, blow line refiners, screen room, LC refiners and highly efficient washing with a multi-stage DD-Washer drum displacer washer, a GF-Filter advanced vacuum drum filter washer and a wash press.

l An energy-efficient lime kiln plant with a capacity of 450 t/d burnt lime, including a lime mud washing and dewatering filter, a feeding system, a shell, riding rings, roller sets and driving mechanism, as well as a burner.

Managing director of Ranheim Paper & Board Øistein Vedahl said: “During the first part of the upgrade of our paper machine, we got to know Toscotec, its people and work methodology.

We are confident that they are the right technological supplier for our strategic investment and are happy to continue partnering with them.”

One of the world’s most northerly paper mills, Ranheim was founded in 1884 and is owned by Fundermax. It has 215 employees and a capacity of about 120,000 tpy of paper and 50 million square metres of solid board.

In brief l Union Paper Mills has ordered automation and quality control systems for the PM2 paper machine at its Dubai mill in the United Arab Emirates. It follows a similar project to upgrade the PM3 machine at Union’s Al Dhafra facility in Abu Dhabi. The new systems will replace the existing DCS and QCS from another supplier and enable the mill to improve operating efficiency and end-product quality. “We have seen good performance of DNA Distributed Control System and IQ Quality Control System at Al Dhafra mill and several other references in the region.

And Valmet’s local service team from Valmet’s United Arab Emirates office provides good and competent service,” says Chander Prakash Sharma, automation manager at Union Paper Mills.

PROJECTS & CONTRACTS 37

Pulp Paper & Logistics

DS Smith’s Porcari mill improves cogeneration efficiency

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six-month project at DS Smith’s Porcari mill at Lucca in Italy to optimise steam and power generation and reduce fuel consumption has been completed successfully by ABB. The mill, located in Tuscany, is a key production hub where DS Smith manufactures a range of packaging products serving the food, e-commerce, retail and industrial sectors. The plant operates two paper machines, as well as a new machine currently under construction and a cogeneration plant, providing thermal and electrical energy to the mill and the national grid.

ABB implemented its Ability Optimax software to control the 100MW cogeneration plant, achieving a four percent reduction in gas consumption, with a reduction in the mill’s carbon footprint of about 13,000 tons per year.

“ABB’s digital solutions use sophisticated plant models to better manage the cogeneration

DS Smith’s Porcari mill in Italy has cut its gas consumption by four percent using ABB’s digital control systems plant operations, helping us to achieve our sustainability targets while increasing profitability,” said Fabrizio Sodini, power plant manager at DS Smith.

Sergio Durando, manager of ABB’s energy industries business in Italy, Greece, Turkey and Algeria, commented: “The four percent reduction in gas consumption and resulting emissions fulfils ABB’s goal of contributing to sustainability.”

ABB added that Ability Optimax also improves the ability to follow a power export plan negotiated with the energy market, with an error reduction of about 90 percent compared to previous operational standards.

The project highlights ABB’s history of working with DS Smith, dating back to the installation of ABB drives, special permanent magnet motors and automation systems for PM2 at

New wood room at Nordic’s Bäckhammar mill to boost production Nordic Paper has ordered a new wood room with chip and bark handling for its Bäckhammar mill in Sweden from Andritz.

The plant will have the capacity to process more than 1.4 million cubic metres of pine and spruce logs a year. Startup is scheduled for the fourth quarter of 2025.

Christian Persson, director of operations at Nordic Paper, says: “The investment will further improve sustainability performance and strengthen the competitiveness of Nordic Paper Bäckhammar mill. The new wood room provides for both strategic flexibility in raw material sourcing and efficiency

gains in production.”

The wood room will include a new debarking and chipping line with steam de-icing in the debarking drum, which ensures high debarking with low losses while saving energy, water use and effluent water load. Chipping in horizontally fed HHQ-Chippers is said to ensure efficient use of

the mill in 2011.

Moreover, the long-standing cooperation at the cogeneration plant, dating back to the early 1990s, facilitated the introduction of ABB’s energy-saving systems.

Since the commissioning, ABB has also been chosen to install a new sectional drives system with high-efficiency drives and motors for the mill’s new PM3 recycled containerboard line, currently under construction. the raw material and provides the highest chip quality on the market.

Nordic Paper is a leading speciality paper producer in Scandinavia. At Bäckhammar, it manufactures unbleached kraft papers in a range of qualities primarily for packaging end-uses.

Raw material is pulpwood from forests in mid-Sweden along with sawmill chips. Products made from paper from Bäckhammar include sacks for flour, carrier bags and bread pouches.

January/February 2024

38 PROJECTS & CONTRACTS

Pulp Paper & Logistics

Fibreline relocation and upgrade for Yueyang Forest & Paper

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ueyang Forest & Paper is having a fibreline relocated and upgraded by Andritz to produce premium quality fibres that will feed a new paper machine at its Yueyang mill in Hunan province.

The pre-conditioning refiner chemical alkaline peroxide mechanical pulp (P-RC APMP) line was originally supplied by Andritz in 2011 to the mill in Yuanjiang city, Hunan province. Andritz will now transfer it to Yueyang city, Hunan province, where it will process mixed hardwood for the production of printing and writing papers.

By adding new high-efficiency equipment and refurbishing existing machines, the upgrade will raise the line’s minimum design capacity

Efficient pre-treatment and optimum chemical impregnation of the wood chips to improve fibre quality at reduced energy and chemical consumption is said to be provided by this refiner from Andritz to 650 admt/d and improve fibre quality while saving energy and chemicals. Start-up is scheduled for the second half of 2024.

Xu Jianhong, project manager for chemi-mechanical pulp lines’ reform department at Yueyang Forest & Paper, says: “Andritz

successfully completed a similar relocation and modernisation project for us in 2018. Their extensive experience, proven technology for mechanical pulping, and highly professional service team were decisive factors and why we chose Andritz again as our

Dezhou Taiding to double its mechanical pulp capacity in China China’s Dezhou Taiding New Material Science and Technology Co has ordered a second chemithermomechanical line for its mill at Dezhou City in Shandong Province.

The Andritz fibreline already installed at the mill supplies the company’s paper machines producing printing and writing paper and board grades. It has been operating since 2021.

Zhang Qingchao, vice general manager of production at Dezhou Taiding, says: “The Andritz P-RC APMP line at our mill has consistently shown top fibre quality, remarkably low energy and chemical consumption, and high operational reliability. It January/February 2024

A second chemi-thermomechanical line has been ordered by Dezhou Taidingin China was clear for us to partner with ANDRITZ again for our capacity increase.”

The new line with a capacity of 400 admt/d will process poplar wood chips into high-quality

mechanical pulp. Andritz will supply the fibreline with key equipment, covering all stages from chip washing to pulp storage.

Start-up is scheduled for the beginning of 2025.

partner for this project.”

Andritz will modernise the line by adding a second stage impregnation and a second bleaching system. A PrimeMSD Impressafiner is said to ensure efficient pre-treatment and optimum chemical impregnation of the wood chips to improve fibre quality at reduced energy and chemical consumption.

In addition, Andritz will rebuild two existing HC refiners, upgrade a sealing system and refurbish three screw presses and two pressure screens used in a former DIP line. This will significantly reduce investment costs while meeting all technological requirements.

Andritz will also provide the supervision of installation, commissioning, start-up, and training.

In brief l An un-named global paper manufacturer has commissioned Voith to rebuild its production line into a state-of-theart production facility for recycled packaging papers.

Commissioning of the line is scheduled for 2025. The line includes a BlueLine stock preparation system, the rebuild of the existing machine into an XcelLine paper machine, as well as comprehensive service agreements and a fabrics package. The project also involves a rebuild of the existing winder for processing packaging papers.

PROJECTS & CONTRACTS 39

Pulp Paper & Logistics

Saica builds new corrugated board mill in Spain

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ork has begun on Saica Group’s new corrugated board mill near Barcelona, with a view to start operations in the spring of 2025.

Located in Sant Esteve Sesrovires, the plant will combine the operations of two current mills: Saica Pack El Prat and Saica Pack Barcelona.

The new project involves an investment of more than €100 million and aims to increase the current joint production of the two mills by up to 45 percent.

Saica says the facility will be a pivotal benchmark for innovation and sustainable packaging products, while addressing evolving market demands and size constraints of its existing facilities.

Additionally, Saica says the investment underscores the group’s long-term commitment to

Construction of Saica’s corrugated board plant near Barcelona has started the southern European packaging market and will ensure Saica’s support for its customers’ plans for growth.

The new factory will be equipped with the latest technology, combining flexography and offset processes. It will also offer significant advances through the digitalisation of customer services.

The land was acquired in 2010 by Saica, which actively participated in the development of the

industrial estate, now occupied by a number of major companies. In 2018, Saica also built and opened a finished-product warehouse on the site.

Saica Group chairman Ramón Alejandro said, “This investment will allow us to have the latest digital technology. We will be able to increase our production capacity and also improve the service we provide to our customers.”

New product launches in Asia for Nippon Paper Crecia Nippon Paper Crecia has launched a new range of tissue products in Japan following the installation of advanced winding systems supplied

by Körber’s tissue business division.

The Perini Constellation and Horizon winding system is said to enable lower bonding pressures and the optimum use of materials, along with the ability to run at high speeds and with less downtime.

The system is being used for the production of ‘Scottie Flower

Pack – lasts three times longer’, a newly-developed range that includes a number of patented products.

Collaboration between Nippon Paper Crecia and Körber goes back to 1996. “Our partnership with Körber Business Area Tissue has continued since then. There are multiple factors behind this choice: the elevated converting speed of the machine and the simplified maintenance, for an extremely diversified production output,” says Mr Takai, technology division manager at

Nippon Paper Crecia.

“In this sense, thanks to Körber, we are free to customise the aesthetics of the finished product, which translates in an ever-increasing and complete offering, giving us the possibility to change its characteristics such as the diameter size, the sheet length and the roll cut.”

The collaboration with Körber is said to further strengthen Nippon Paper Crecia’s competitive position in the family-care sector in Asia Pacific markets.

The current facilities in Barcelona and El Prat will continue to operate until the new mill opens. They will then gradually transfer production to the new facility, ensuring continuity of service. The workers at both plants (194 and 100 respectively) and their representatives are involved in this transition process, and all will be offered the opportunity to transfer.

In brief l Dissolving pulp producer Sappi Saiccor has signed a three-year service contract with Andritz for the two recovery boilers at its Umkomaas mill in South Africa. The two boilers produce 230 tons of steam per hour at 490 deg C and a pressure of 86 bar and have been operating since 2008 and 2021 respectively. Saiccor says the service agreement will help the mill maintain safe and efficient operation while improving reliability and availability.

January/February 2024

40 PEOPLE

Pulp Paper & Logistics

New chair for European paper industry association

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arco Eikelenboom has succeeded Ilkka Hämälä as chair of Cepi, the Confederation European Paper Industries, an influential trade association in the forest and biobased industry sector.

Eikelenboom’s two-year tenure at the Brussels-based organisation started at the beginning of

January. Since 2021 he has been chief executive of Sappi Europe, a leading global provider of sustainable wood fibre products and services that is part of Johannesburg-based Sappi Ltd. He has held a number of highlevel positions within Sappi, starting his career in the company in 1997.

Outgoing chair Ilkka Hämälä,

Metsä Fibre appointments at Kemi mill

Pihlajaniemi. The new position of the current vice president at Kemi Board Mill, Timo Ahonen from the beginning of June, will be announced later.

Two appointments have been made by Metsä Fibre at its new Kemi bioproduct mill in Finland, said to be the most efficient wood processing plant in the northern hemisphere.

Pekka Kittilä has been appointed as mill manager from the beginning of February, having previously worked as technical director of the mill project. In his new position, Kittilä will report to Metsä Fibre’s svp for pulp production.

Tomi Seppä will become project director at Metsä Board from the beginning of February, after which he will move to the position of vice president of Kemi Board Mill from the beginning of June. Seppä is manager of the Kemi bioproduct mill. In his new position, Seppä will report to Metsä Board’s svp of production and technology, Harri

Pekka Kittilä and Tomi Seppä are moving up at the Kemi mill January/February 2024

chief executive of Metsä Group, has been a strong supporter of a more open dialogue between the industry and the EU Institutions, and helped launch Circular Choices, a coalition for a more competitive and ambitious EU bioeconomy.

Eikelenboom takes over as EU Institutions prepare for an election period and the start of a new

New financial chief for Monadnock Paper Mills Daniel Burke has been appointed as chief financial officer the treasurer at Monadnock Paper Mills, the oldest continuously operating paper mill in the United States, following the retirement of Andrew Manns.

Burke has more than 22 years of financial management experience in the manufacturing and distribution industries, most recently as corporate controller at Velcro Companies.

“We are truly grateful for Andrew’s contributions over the years and wish him well as he transitions into his retirement,” said Richard Verney, chief executive Monadnock Paper Mills.

“We are confident Mr Burke’s experience and strategic vision will contribute significantly to Monadnock’s continued success and growth, and we are excited to welcome him to the team.”

Daniel Burke, new financial chief at Monadnock Burke said he looked forward to the role of chief financial officer and treasurer at Monadnock. “I am excited about the opportunity to lead in this capacity and contribute to the company’s longstanding commitment to sustainability, ensuring that we continue to make environmentally responsible choices in all aspects of our operations,” he added.

Marco Eikelenboom, the new chair at Cepi mandate for Members of the European Parliament and a new College of EU Commissioners.

Association (ABRE), is the first woman in the WPO’s top job.

Active in the packaging industry since 1996, when she started Bryce Corporation USA, Pellegrino has an MBA with a speciality in environmental science.

Says Pellegrino: “As president, and working closely to WPO’s board members and Secretariat, I aim to strengthen WPO’s strategic partnerships with international bodies, to increase the participation at global events, conferences and trade shows raising the voice of the packaging industry, and at the same time explore different key topics for the organization and for the sector such as governance, technology and innovation.”

Pellegrino heads up World Packaging Organisation Luciana Pellegrino, was appointed as president of the World Packaging Organisation (WPO), at its recent board meeting in Cape Town.

Pellegrino, general manager of the Brazilian Packaging

New president of the WPO Luciana Pellegrino

10–11 April 2024 | Messukeskus Helsinki Expo and Convention Centre

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Pulp & Beyond offers new encounters, inspiration, networking and business possibilities for marketing global and sustainable solutions, products and services within the forest-based bioeconomy. The event provides the widest available showcase on the latest trends and innovative new products within the forest-based bioeconomy, supporting learning, employer branding and competence development.

CONTACT Hanna Mårtensson, Sales Manager +358 40 565 1433 hanna.martensson@messukeskus.com

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