Decrease production cost
Material efficiency is part of sustainable development, and taking it into account is now more important than ever due to the growing scarcity of natural resources. Material efficiency covers the minimization of raw materials used in the production process, selection of the most economical raw materials possible, and the reduction and recycling of waste to minimize the amount of unutilized material.
Why is material efficiency so important? Because it is a major cost factor for pulp and paper mills since raw materials represent about 50% of total operating costs. It also provides an opportunity to boost profitability by minimizing the amount of waste, and related costs. By minimizing waste and recycling waste material, producers are able to meet global agreements and environmental protection goals, and thus help to promote sustainability.
Minimized use, maximized lifetime
Valmet’s material efficiency solutions help pulp and paper mills to save raw material costs by minimizing the use of expensive raw materials (e.g. bulk-saving solutions at the press and drying sections and calenders) and reducing the consumption of chemicals (e.g. OptiCell flotation unit).
Maximizing the lifetime of consumables through optimized design (e.g. AttackBar, NimCat screen basket, FlexSeal, or coater blades) and reusing reconditioned equipment (e.g. refiner reconditioning and refiner exchange program) helps to cut equipment costs. Recycling such consumables as doctor blades and rod beds also saves money.
Our new modular machine concept, OptiConcept M, shows how all-around materials use optimization reduces construction costs and space needs, as well as saves energy and raw materials. This optimized compact paper machine design reduces frame weight and the environmental impact of the machine significantly.
Material efficiency means producing the same end result with reduced amounts or lower grades of raw materials. This applies particularly to paper and board manufacturing, but also to certain aspects of machinery construction.
The forming section rebuild with Valmet's shoe blade technology improved formation and reduced filler two-sidedness at Sappi Somerset PM3 at Skowhegan, USA. The use of expensive wet end and coating materials were significantly reduced.
New headbox technology enables raw material cost optimization at Dong Il Wolsan PM1. 30% less ess starch is needed and worse quality raw materials, such as OCC waste, can be utilised without compromising strength properties.
JSC Arkhangelsk PPM, the biggest containerboard manufacturer in Russia, has recently invested significantly as they strive to increase capacity, product quality, cost efficiency and sustainability. OptiFiner Pro refiners helped the Novodvinsk mill to meet its targets with an upgraded stock preparation system.
Water removal at the forming or press section is significantly cheaper than at the dryer section. Since removing one liter of water from the sheet at the dryer section costs five times more than at the press section, it pays to optimize dewatering at an early stage.
Paper and board makers have been focusing their attention on increasing their output in tonnes. A paper machine is not considered to be functioning well if its output in tonnes drops, even if this is due to improved bulk and reduced use of fibers. Environmental considerations and cost competition are forcing to rethink the processes. Boxes are not made of tonnes but board sheets.