Kıvanç Paper PM 1: Building the responsible future of packaging with cutting-edge technologies

The board making line delivery included an OCC line, stock preparation and white water treatment, board machine PM 1 from headbox to reel and winder, and services and automation for the entire mill. The line started up successfully in the fall of 2024, and the results have been world-class: the board’s quality and strength properties are superior compared with those of competitors. “We are doing something different than other paper mills in Türkiye. We are using the same raw materials and the same chemicals, but we are producing much stronger board than our competitors,” says Ali Karagöl, Technical Director at Kıvanç Paper.

We are doing something different than other paper mills in Türkiye. We are using the same raw materials and the same chemicals, but we are producing much stronger board than our competitors.

Ali Karagöl, Technical Director at Kıvanç Paper, and Ziya Kıvanç, Chairman of the Board at Kıvanç Group.

Background in the textile industry

Although Kıvanç Paper is a newcomer to papermaking, the company brings decades of experience from the textile industry, giving it a strong foundation in a highly competitive business environment. Operating in a sensitive industry such as textiles is challenging: it is heavily influenced by trends, global consumption patterns, and political fluctuation. According to Ziya Kıvanç, the Chairman of the Board at Kıvanç Group, thinking ahead and diversifying the business risk are important. “As Kıvanç Group, we have never focused solely on today; we have always thought at least ten years ahead. In textiles, we built a system that supplies major European and American fashion brands with high-quality sustainable fabrics. Kıvanç Paper is a natural extension of this vision, of long-term thinking, and creating value for our country,” says Kıvanç.

At the core of the company’s values is a commitment to the creation of a more sustainable packaging industry, while addressing the growing demand for packaging. The mill produces recycled fluting and liner by transforming wastepaper into raw material and contributing to the circular economy. According to Kıvanç, reducing the environmental impact of the business requires leveraging innovative technologies. “We use state-of-the-art equipment that delivers high efficiency and low emissions. In other words, we are not only addressing the growing demand for packaging; we are doing so in a way that fully aligns with sustainability requirements such as the European Green Deal,” says Kıvanç.

The mill produces recycled fluting and liner by utilizing recycled wastepaper as raw material.

Single supplier for stock preparation and board machine

When planning the board machine investment, Kıvanç Paper wanted to choose technologies that would make a difference in the future and provide a competitive advantage. PM 1 includes several new innovations that can’t be found anywhere else in the world.

From the very beginning of the project, it was very important for Kıvanç Paper to have the same supplier for both the OCC line and board machine to ensure the seamless usability of the machine line. “We selected Valmet so we would have the same supplier for all divisions of the project,” says Karagöl. “We also had discussions with many other suppliers in the beginning, but we have previous experience of Valmet, and they really are the best when considering board machine suppliers.”

The seamless operation of the mill and technologies is ensured with a Valmet DNA automation system. “When considering the overall efficiency of the board machine, automation’s role is very important. Right now everything is being digitalized. So a good understanding of production is very important,” Karagöl says.

Energy-efficient OCC line with Valmet Drum Pulper

Part of Valmet’s delivery was an Old Corrugated Containers (OCC) line, a bale pulping line with Valmet Conical Refiners and a high-consistency pulping line. A white water system with a saveall broke thickener, under-the-machine pulpers, and several Valmet Conical Refiner units were also delivered. The main benefit of the OCC technology is its low energy consumption. “Due to Valmet’s good equipment, we do not need to use energy-intensive processes such as dispersion to remove stickies from the system,” explains Karagöl. “Valmet Drum Pulper, selected after careful evaluation and reference visits, provides gentle slushing without chopping fibers or breaking contaminants into smaller pieces that could pass to later stages.”

The line is further supported by proven coarse screening and low-consistency cleaning technologies, including Valmet Twister Hydrocyclones. “We can run the Twister cleaners at up to 2–2.5 percent consistency, which gives us great flexibility. The equipment has been reliable, with no major maintenance issues,” Karagöl says.

Valmet’s delivery for the stock preparation included an Old Corrugated Containers (OCC) line, a bale pulping line, and a high-consistency pulping line.

Wet end technologies reducing raw material and energy consumption

Kıvanç Paper chose an OptiFlo Layering Fourdrinier headbox with Aqua layering technology to ensure the quality of the board and reduce material costs. “With Aqua layering technology, you can dose the chemicals less than the other technologies because you are directly dosing inside the layers of the paper. It also allows you to play with the top and bottom layer ratio. The layer purity, especially in the liner grades, has been excellent,” says Faruk Özşerbetçi, Paper Mill Director at Kıvanç Paper. Together with hybrid former, the layering headbox offers flexibility when producing multiple grades.  

The layer purity, especially in the liner grades, has been excellent.

To reduce the energy consumption of the wet end, Kıvanç Paper invested in a new digital solution Valmet Uhle box Vacuum management system. The application has been developed in collaboration between Kıvanç Paper and Valmet during the project. It automatically regulates the vacuum levels in the press section to ensure consistent dewatering performance, making operators’ work easier. “It is a very good tool to use. It allows you to use less energy in the vacuum area, which is the second-biggest energy consumer in the paper machine. The vacuum management system also reduces the process variation because we always know what the vacuum level is,” explains Karagöl.

PM 1 has been running with Valmet’s paper machine clothing, and the cooperation will continue through a fabrics agreement in the future.

Long-term cooperation ensuring stable clothing performance

Ever since the start-up, the machine has been running with Valmet Paper Machine Clothing. Kıvanç Paper has been especially satisfied with the support they have received from Valmet with the clothing, and plan to continue the cooperation through a fabrics agreement in the future. “It can take time to find the correct configuration with felts and forming fabrics. That is why we want to use well-known products and suppliers so we can ensure their performance,” says Ramazan Tekin, Production Director at Kıvanç Paper.

Faruk Özşerbetçi, Paper Mill Director at Kıvanç Paper, and Ramazan Tekin, Production Director at Kıvanç Paper.

Newest drying and sizing innovations in the world

The dryer section of PM 1 features a new compact geometry where the vacuum roll is closer to the dryer cylinder. This shortens the distance between the two, enhancing runnability and drying efficiency. “It is a very efficient dryer section. When you look at steam consumption per tonne, it is very good, less than guaranteed figures,” says Tekin. “Also, our tail threading is so fast. That’s why we haven’t seen any bottlenecks or problems with this,” says Özşerbetçi.

Faruk Özşerbetçi, Paper Mill Director at Kıvanç Paper, and Ari Hiltunen, Senior Paper Technology Manager at Valmet, inspecting the novel compact dryer concept.

To ensure the strength properties of the board, PM 1 includes the first OptiSizer Hard sizer in Türkiye. “We chose a hard nip sizer to achieve a stronger product. Compared with traditional sizers, with the same nip load and the same amount of size, you can have more strength in the end product,” says Özşerbetçi. Investing in innovation was important for Kıvanç Paper. “We could have chosen a film sizer, but if you want to do something better and remarkable, you need to take some risks and believe in new technology,” Özşerbetçi continues.

OptiSizer Hard ensures the board’s strength properties and eliminates the need for calendering.

Collaboration at its best

Overall, the project has been successful, setting a high standard for other papermakers globally. “The line has been running well from the very beginning. We achieved 75 percent of the design speed very soon after the start-up, and we were able to produce sellable board within a few days,” says Tekin. The success of the project comes in many ways from the extensive knowledge and experience of both Kıvanç Paper’s and Valmet’s experts. Close cooperation between the companies has allowed innovation and product development during the project, which is very important with so many new technologies. “We are happy about the support we received during the project. If we needed to do something, or if we needed help during the running, we asked Valmet, and they immediately replied to us,” says Özşerbetçi.

Cooperation between Kıvanç Paper and Valmet has been exceptional during the project.

Scope of supply

Valmet’s delivery for the board making line’s stock preparation consists of an OCC line, stock preparation, and white water treatment, including a Valmet Drum Pulper, Conical Refiner Conflo units, Twister Hydrocyclone units, a saveall broke thickener, screening technology, and under-the-machine pulpers.

The Valmet-supplied board machine includes state-of-the-art technologies, from headbox to the reel and winder. The wet end of the machine includes an OptiFlo Layering Fourdrinier headbox with Aqua layering technology, an OptiFormer Hybrid forming section with shoe blade technology, and an OptiPress Linear press section. They are followed by an OptiRun compact dryer section. The finishing technologies of the machine consist of an OptiSizer Hard size press, an OptiCalender Hard calender, an OptiReel Linear reel, and a OptiWin Drum two-drum winder. A supply system for the sizer and air systems was also delivered by Valmet, including process ventilation systems featuring an OptiAir Hood high-humidity hood and OptiAir Recovery heat recovery.

The process technology is supported by digital services, automation systems, and other services such as paper machine clothing.

Text: Veera Silakoski

Photos: North Arrow Films