Customer case:

Nippon Dynawave: sustainable board with less CO2 emissions and fibers

Nippon Dynawave wanted to go towards a more sustainable board production. They succeeded in reducing greenhouse gas emissions and using less fibers for the same amount of board with the Valmet-supplied metal belt calender.

Sustainability is very important to our customers and to our parent company Nippon Paper Industries. We're focused on reducing greenhouse gas emissions and source reduction, meaning less fibers for the same amount of board that we provide to our customers.

Putting a metal belt calender on our paper machine allowing us to use less fibers to make the same quality board for our customers is really revolutionary to this business."
John Carpenter, President, Nippon Dynawave Packaging
The main drivers for this project was to improve the competitiveness of our board, really focusing on the basis weight and improving the printability of the board.

We chose Valmet as a supplier after doing extensive pilot work - investigating the technical solution they proposed."
Andrew Cooper, Vice President Operations, Nippon Dynawave Packaging
Since the rebuild and the start-up of the metal belt calender, the day-to-day operations are quite simplified. The calender is repeatable, it seems to be reliable. There are only two parameters that the operators generally work with to adjust the paper quality.

The results with the metal belt calender were actually better than with the pilot scale projections. So it has been quite an asset to Nippon Dynawave to make better paper while reducing fiber demand."
Perry Brandenburg, Machine Manager, Nippon Dynawave Packaging
Summary of the project
Location Nippon Dynawave Packaging, Longview, Washington, United States
Solution

Nippon Dynawave paper machine PM 3 was rebuilt to meet the market demands. A new pulp drying line was also installed to increase pulp production capacity.

- OptiCalender Metal Belt calender

- Optireel Primary center-diven reel

- New pulp drying line

Results

Nippon Dynawave's paper machine PM 3 was rebuilt to improve the quality and to reduce basis weight of the board. A new pulp drying line was also installed to increase pulp production capacity.

  • Metal belt calender improved the board quality. Nippon Dynawave was able to reduce the fiber usage because the calender retains bulk of board.
  • A new pulp drying line was also installed to increase pulp production capacity, which lower the costs and increased the sales volume. 
Keywords Paper & board, Rebuilds, improved quality, improved sustainability, capacity increase, North America
   
Technical data  
Grades Liquid packaging board; the bleached paperboard are used to make cartons and cups for liquids such as milk, juice, coffee and sake (source Nippon Dynawave)
Technical information Annual capacity 300,000 tonnes, which is equivalent to 6 billion liter-sized milk cartons (source Nippon Dynawave)
Start-up Pulp drying line and reel 2020
Metal belt calender 2021