Seven steps for designing, implementing and measuring successful sustainability initiatives in board and paper mills

Climate change is reshaping the industry, prompting a need for greater agility and a willingness to explore more sustainable ways of operating. Fortunately, board and paper technology has advanced to maximize efficiency and optimization, making it possible for mills to reduce their environmental impact in many ways while maintaining or increasing production, including:

• Improving energy efficiency
• Controlling air pollution
• Using alternative fuels
• Reducing water use
• Reducing raw material consumption

Sustainability initiatives are critical to executing a successful sustainability strategy that meets targets. Here are seven steps for designing, developing, implementing and measuring practical sustainability initiatives.

Today’s innovations make it possible for mills to reduce their environmental impact in many ways, including improving energy efficiency, minimizing water usage and reducing raw material consumption.

1 - Identify focus of the initiative

When determining the focus of a sustainability initiative, it’s important to define the project by selecting a specific area to address. Some mills may want to concentrate on energy efficiency or water consumption, while others may want to direct their attention toward fiber and other raw materials.

Typically, the greatest opportunity for most mills is energy reduction. One reason is because some of the North American board and paper industry still operates using 1960s- and 1970s-era equipment. That leaves a 50- to 60-year gap in technological innovation and the resulting gains in efficiency and performance.

For example, the forming section is the biggest user of vacuum energy on paper and board machine lines. Until recently, forming section drainage has relied on decades-old techniques such as gravitation and dragging vacuum elements set along the forming fabric’s journey. Board and paper technology has come a long way. Recent innovations in modern sleeve roll technology or shoe press rebuilds can make mill processes significantly more energy-efficient than traditional suction roll technology or older press roll designs. Sleeve roll technology does not require vacuum energy, and therefore, it saves energy in both the vacuum system and drives of the forming section.

2 - Determine the targets, then begin measuring and auditing

Once a mill has determined the focus of its sustainability initiative, it can identify key targets of the process in question and then measure and audit them. Then, mills can begin to calculate the current environmental impact of the process.

Consider, for example, that a mill wants to improve the energy efficiency and reduce the emissions of a specific process. The key targets of this initiative are:

• How much energy the process uses
• How much carbon dioxide (CO₂) is generated to produce that energy

To determine CO₂ emissions, it’s important to look at where the energy for the process comes from. Each energy source has a different impact on the environment and generates a different level of emissions when used to produce energy. A fully integrated paper mill may produce much of its electricity from sustainable resources such as black liquor. In comparison, a recycling facility may be coupled with a local municipality that produces electricity through any number of methods, including coal, nuclear power, hydropower or wind energy.

By improving and updating mill technology, the board and paper industry can significantly decrease its CO₂ emissions and overall environmental impact, which can lead to a dramatic effect on a global scale.

Once the energy source of the process has been determined, it’s important to determine how much energy it consumes over a given period of time. Using that measurement, a mill can calculate the energy efficiency of its materials and production, as well as its emissions for the process. Emissions are typically measured in tons of CO₂ for tons of paper or tons of CO₂ over the area sold.

These calculations form the audit to identify the baseline of current process energy efficiency and environmental impact.

3 - Benchmark key values

Once a mill has completed audits for its sustainability initiative, it can then use them for benchmarking key values, such as energy use and production capacity.

There are a few ways to complete benchmarking. Some OEM suppliers offer support through annual production and energy surveys. Another way to complete benchmarking is to use standard guidance provided by industry organizations, such as the Technical Association of the Pulp and Paper Industry (TAPPI) Technical Information Papers (TIPs).

Some TAPPI TIPs that can help with performance and sustainability benchmarking include:

• TIP 0404-47 – Process Evaluation and Optimization
• TIP 0404-61 – Paper Machine Shower Recommendations
• TIP 0404-63 – Paper Machine Energy Conservation

By establishing a baseline for key values, a mill can assess how it stands in comparison with others in the industry as well as its own future measurements after initiative improvements.

4 - Explore sustainable alternatives while maintaining or increasing production

After evaluating the performance and sustainability of the existing technology and process, a mill can begin to explore more sustainable alternatives and their projected outcomes. These alternatives may include different processes, resources or technology, a different approach to making paper or changes to the product design itself. There are some proven alternatives for common sustainability initiatives that can reduce environmental impact while improving productivity.

To reduce energy consumption, alternatives include:

• Sleeve roll in plies combining position – This alternative to traditional suction press rolls requires less drive and vacuum power, which can reduce carbon emissions and increase production capacity.
• Shoe press modification – This method results in greater dryness after press, reducing steam and associated CO₂ emissions while increasing production capacity. When removing water, pressing is 10 times more energy-efficient than evaporation.

To update energy sources, alternatives include:

• Air dryer heating unit electrification – This update can be performed when rebuilding or adding air dryer capacity.
• Heat recovery – This method offers steam savings and associated CO₂ reduction
• Steam versus electricity when higher dryness with shoe press

To optimize water consumption, alternatives include:

• Traversing wet end showers – This method can replace full-width, high-pressure shower pipes.
• Ultrafiltration system after disk filter – This can save water.

It’s possible to do more with less with a more advanced or a more technologically driven solution.

5 - Determine project feasibility and define KPIs 

It’s critical that sustainability initiatives also align with a smart business strategy. By determining the feasibility of a project, it’s possible to minimize risk and maximize success.

To determine the feasibility of a project, it’s important to get a quote that details the cost of the project and to confirm a pilot trial. Doing this makes it possible to estimate the cost savings gained by the process and calculate return on investment (ROI).

Once a project has been determined as feasible, a mill can identify key performance indicators (KPIs) to measure its success and detect areas that may need additional adjustment. These are usually correlated to the benchmarked values from step three. For instance, if a mill wants to reduce energy and water consumption, the KPIs may be energy use, water use and production capacity.

How to calculate productivity and sustainability within the process can differ from mill to mill and project to project.

6 - Execute the project and begin running the new or updated process

At this stage, the new changes to the process are applied. This might be new equipment, a new resource or new methodology and is usually done in collaboration with an OEM supplier.

For instance, when leading board and packaging producers wanted to reduce energy, water and fiber consumption while increasing production capacity, they have partnered with Valmet to install the following:

• Aqua layering technology
• Sleeve roll technology
• Shoe press modification to improve roll efficiency
• Metal belt calendaring for longer nip and lower intensity

Once installed, the new or updated process can begin running and teams can begin to track KPIs.

7 - Measure success and look for new opportunities

After processes have run for a given period of time and KPIs have been tracked, it’s time to measure the success of the initiative. To measure the success, teams usually compare benchmarked values of the original process and KPI values of the new process.

Using the example above:

• The aqua layering technology provides stratified layers and better response to chemicals such as starch.
• The sleeve roll technology reduced the amount of vacuum energy needed. For mills that use older vacuum pumps, these pumps typically require a lot of maintenance, and this makes it possible to minimize service time as well.
• The shoe press modifications improved roll efficiency and metal belt calendaring provided longer nip and lower intensity. Together, these updates improved printing properties as well as some coating properties

Overall, producers have seen the following estimated savings:  

• A 30% starch reduction
• A 32% energy reduction (vacuum)
• A 40% energy reduction
• A 5% fiber reduction

As mills achieve project ROI, they can begin to look for new opportunities to improve efficiency and reduce environmental impact.

Do more with less

Sustainability initiatives present mills with the opportunity to find alternatives and advance mill performance. By improving and updating mill technology, the board and paper industry can significantly decrease its CO₂ emissions and overall environmental impact, which can lead to a dramatic effect on a global scale.

As mills undertake sustainability initiatives, they don’t have to do it alone. Those that work with an expert OEM supplier from the beginning are at an advantage. Whether an initiative drives a new board and paper mill investment or improves the performance of existing mills, it’s important to partner with an OEM supplier that is making demonstrable progress on its own sustainability initiatives and has a proven track record of helping mills achieve theirs. Look for partners that are developing new technologies to enable carbon-neutral board and paper production and have had success reducing energy consumption, water consumption and material consumption while increasing production capacity.

Improving sustainability and reducing environmental impacts is not a once-and-done process. So, it also makes sense to partner with OEM technology suppliers with proven service programs and expertise to continuously improve your operations, ensuring a minimized environmental footprint over the long term.

Board and paper mills that make strategic investments in environmental sustainability, operational excellence and safety can achieve financial gains while promoting a greener future. As mills take the first step of their sustainability initiatives, they’re also taking the first step toward advancing overall mill efficiency. Because when mills become more efficient, they become more sustainable. The key is to get more from less.