Aiming for net-zero with every decision – VPK Group’s grade conversion in Alizay, France

In June 2021, VPK Group acquired Double A’s Alizay mill in Normandy, France. This acquisition addressed the growing gap between VPK’s corrugated packaging and papermaking operations, creating a need for a strategically located new paper mill. The new mill’s goal was CO2-neutral production in a strategic location near major waste hubs like Paris. The Alizay mill met all these requirements perfectly. Originally producing fine paper grades, the mill’s paper machine has been rebuilt to produce recycled lightweight containerboard grades. 

Safety has been the top priority throughout the rebuild project. Daily safety discussions have led to continuous improvements. “Creating a safety culture was truly a joint effort between Valmet and VPK during the paper machine rebuild,” says Alexis Zenner, Chief Operating Officer of Paper Division at VPK Group. 

Ensuring product quality has also been crucial. The machine has produced containerboard with good strength properties from the very first reel. “Today, all the specifications are on target. The properties are good, and our main focus is always on delivering the best quality to our customers,” says Jamila Derraz, General Manager at VPK Paper Normandie. 

The old paper machine in Alizay was converted into a board machine producing recycled lightweight containerboard grades.

Sustainability at the core of the business

Environmental sustainability lies at the core of VPK Group’s business, with carbon neutrality a key goal. The group has validated near- and long-term science-based emissions reduction targets with the Science-Based Targets initiative (SBTi) and is committed to achieving net-zero greenhouse gas emissions across its value chain by 2050 under the Net-Zero Standard. 

“When you’re converting an existing line, carbon neutrality must be one of your decision criteria.” 

“This is a tough target. It means that when you’re installing a new paper machine or converting an existing line, carbon neutrality must be one of your decision criteria,” says Alexis Zenner. “The Alizay paper mill now uses biogas and biomass-based steam. This makes both the paper machine and the corrugator net-zero in energy use.” 

“We still have some indirect CO2 emissions, but we’re working to reduce them every day. For example, we’ve started transporting our raw materials to Alizay by river to avoid using trucks,” adds Jamila Derraz.

Major changes in the wet end 

The grade conversion rebuild involved modifications and upgrades to the wet end and dryer section. 

“We added a dilution profiling system to the existing headbox to improve the paper profile. This has been a significant upgrade for the machine. We’ve also improved the whole vacuum system to increase capacity and improve the dry content of the web at the end of the forming section,” explains Baptiste Noulette, Production Engineer at VPK Paper Normandie. 

Wet end modifications ensure high paper quality. 

The biggest modification to the wet end was the installation of a new OptiPress Center press section, which removed one press from the machine. With the new shoe press, the paper machine has achieved a dryness rate of 54 percent at the end of the press section.  

“We only have three presses now, including the new shoe press, which has increased the sheet’s dry content at the end of the press section. These modifications will certainly enable us to have fewer breaks and enhance production reliability and machine speed,” says Hervé Letondeur, Maintenance and Project Manager at VPK Paper Normandie. 

In addition to the wet end modifications, VPK has been particularly pleased with the reliability and time saving benefits of the runnability and ropeless tail threading systems. “These systems significantly reduce the time spent on tail threading,” comments Baptiste Noulette. 

All automation on a single platform  

Valmet delivered a comprehensive automation package to the Alizay mill. Before the conversion, the mill had multiple distributed control systems from various suppliers. The automation of the board line was fully converted to Valmet DNA.

 “All the machinery in the mill is now programmed in Valmet DNA.”

“The key benefit of automation is having everything on a single platform. All the machinery across the mill is now programmed in Valmet DNA,” says Alexis Zenner. 

Quality is controlled through the Valmet IQ Quality Control System – for example, with profile and weight regulation at the headbox and scanners before both the sizer and the reel. 

“The QCS helps us achieve very high-quality profiles,” adds Baptiste Noulette.  

Cooperation is the key to success 

Cooperation has been excellent from the start and has remained consistently strong. Conversions are inherently complex, requiring papermakers to carefully consider what can be kept, and what needs upgrading or renewing. Good teamwork is essential for getting everything right. 

“Cooperation is the key to success in any project. Thanks to Valmet’s expertise and commitment, we’ve always received the right support and resolved any issues quickly,” emphasizes Jamila Derraz. 

“Here at VPK, we consider this project a repeat order from Valmet, and we’d gladly work with them again,” concludes Alexis Zenner. 

Text: Salla Aalto