suzano continues to plant its future with trees and
TRANSCRIPT
www.paperage.com
SEPTEMBER/OCTOBER 2021
Suzano continues to plant its future with trees and sustainable business operations
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3SEPTEMBER / OCTOBER 2021
c o n t e n t s SEPTEMBER/ OCTOBER 2021, VOLUME 137, NUMBER 4
22
F E AT U R E S
22 Inspired By Trees Through nearly 100 years, Suzano has evolved
to become the largest producer of pulp in the world and a leading manufacturer of paper in Latin America; and the Brazilian forest products company continues to plant its future with trees and sustainable business operations.
26 An Insight to AGV Implementation in the Pulp and Paper Industry
The in-house transportation and warehousing of paper rolls, pallets of sheet products and pulp bales are 24/7 operations where automated logistics technology can offer great opportunities for increased efficiency and safety. Today, automated guided vehicle (AVG) techniques and capabilities make them more cost effective and more versatile than ever before.
C O L U M N S
20 Advancing the Circular Economy: One Innovation at a Time
By definition, The Ellen MacArthur Foundation describes the circular economy as an economy “that is restorative and regenerative by intention [and] by design.” Based on these principles, the circular economy aims to eliminate waste, keep products and materials in use, and regenerate natural systems. So, how exactly does the paper and wood products industry contribute to the circular economy?
D E P A R T M E N T S
4 Editor’s Note
6 Industry News
30 Market Insight Accounting for 25.09 million tonnes in 2021,
the specialty papers market is dynamic and will present multiple lucrative diversification oppor-tunities across the next five years. This includes delivering new grades that will allow companies to deliver on commitments to substitute away plastic in packaging.
S E R V I C E S
29 Classified Ads
29 Index of Advertisers
SEPTEMBER / OCTOBER 2021VOLUME 137, NO. 4
EDITOR IN CHIEF Jack O’Brien
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Doing Goodeditors note
4 SEPTEMBER / OCTOBER 2021
Too many times large companies aren’t given enough credit for the good they do in the commu-nities where they operate. I had the opportunity of writing an article for this issue of PaperAge about Suzano. To be fair, the article barely brushes the surface of Suzano and the wide range of products it produces and the sustainability / environmental initiatives it has in place. What I would like to touch on is Suzano’s commendable response to COVID-19 in Brazil. As the company points out, its actions are based on three pillars: People, Society, and Business Continuity, and it is “Society” that I’ll key on. Since the onset of the pandemic, Suzano has taken a series of measures to help protect its employees and the people of Brazil, including:
• Donation of tissue paper, napkins and disposable diapers produced by Suzano to needy regions.
• Acquisition of 159 ventilators and 1 million medical masks for donation to the federal and state governments.
• Participation in a joint effort with Positivo Tecnologia, Klabin, Flextronics and Embraer to support the Brazilian company Magnamed in manufacturing ventilators, which were delivered to the Brazilian government. Suzano invested R$9.6 million in this action in 2020.
• Construction of a field hospital in Teixeira de Freitas, Bahia, jointly with Veracel, which was delivered to the state government and inau-gurated in July 2020.
• Partnership with the vocational school Fatec in Capão Bonito to produce hand sanitizer.
• Forklifts lent to transport the donations received by the Red Cross.
• Maintenance of all direct jobs.
• Maintenance for 90 days (until the end of June 2020) the payment of 100% of the payroll
expenses of employees of service providers whose operations were suspended because of the pandemic, in order to protect jobs.
• Creation of a support program for small suppliers, a social program to help small farmers sell their produce via a home delivery system in 38 communities assisted by Suzano’s Rural Land Development Program (“PDRT”) in five states, and a social program to produce 125,000 masks in local communities for donation in five states.
• Launch of a support program for small and mid-sized paper clients called “We’re Together” to ensure that these companies have the financial and managerial capacity to resume operations.
• Support for the State Government of Maranhão in setting up the Imperatriz Temporary Hospital, donating R$3 million.
• Supply of 280,000 m3 of oxygen to the State of Amazonas.
• Construction of a new treatment center for COVID-19 in São Paulo in partnership with Gerdau, BTG Pactual, Península Participações and through joint efforts with Hospital Israelita Albert Einstein and the Municipal Government of São Paulo.
• Donation of oxygen concentrators, acquired in a joint effort involving Suzano, Bradesco, BRF, B3, Embraer, Gerdau, Grupo Ultra, Itaú Unibanco, Magazine Luiza, Marfrig, Natura & Co and Unipar, to the Health Ministry, which is tasked with the logistics of distributing the devices. Donation of 66,000 m3 of oxygen to the city of Imperatriz in Maranhão and 1,300 m3 to Aracruz in Espírito Santo.
As the company emphasizes, one of its culture drivers is, “It’s only good for us if it’s good for the world” — a mantra Suzano has fortified through action.
As a full-line supplier, we are providing customer-centric solutions from a single source for an efficient and sustainable papermaking process. By offering holistic project packages that not only combine a unique product portfolio, services and digitalization but also comprise project management and consulting, we assume the comprehensive project responsibility for you and significantly reduce complexity and interfaces. Together, we focus on making the world better with paper. voith.com/paper
Discover the potential of holistic papermaking solutions.
6 SEPTEMBER / OCTOBER 2021
Ahlstrom-Munksjö announced to employees on Sept. 14 that it plans to temporarily idle #8 Paper Machine in December 2021, along with its #20 Supercalender and #21 Rewinder in July 2022 at its Rhinelander, Wisconsin Plant in the United States.
#8 Paper Machine has a capacity of 14,000 tons per year. Addie Teeters, Head of Marketing Communications & Public Affairs for Ahlstrom-Munksjö, told PaperAge that “#8 paper machine produces various specialty paper grades for multiple markets.” The total number of people affected is yet to be determined based on retirements and other potential job assignments. “In a very competitive marketplace, we must continue to provide cost-effective and innovative products, challenging our machine capabilities to generate optimum results,” said Robyn Buss, Executive Vice President of Ahlstrom-Munksjö’s Food Packaging & Technical Solutions Business Area. “Our robust manufacturing platform is well-positioned for continued success. By utilizing several other machines in our regional system, we will provide our customers with the level of service required to meet their needs.” The Rhinelander, Wisconsin plant has approximately 500 employees and was founded in 1903.
Pratt Industries announced plans to invest $400 million in a new 100% recycled paper mill in Henderson, Kentucky. This represents the largest single investment by the company in its history and will create more than 320 full time jobs plus an additional 700 in the construction phase. The Henderson mill will produce more than 1500 tons per day of recycled contain-erboard. It will be designed to use even less water, electricity and natural gas than its sister mills in Georgia, New York, Louisiana, Indiana and Ohio. “It will be the world’s most advanced, environmentally-friendly 100% recycled paper mill,” said company owner and execu-tive chairman Anthony Pratt. “And it means Pratt Industries will have built 6 of the last 8 paper mills in the United States.” Construction on the 450,000 sq. ft. mill is expected to begin in March of 2022 with a
startup date scheduled for fall of 2023. In a separate project, the company also announced plans to build a 700,000 sq. ft. corrugated box plant adjacent to the new mill. Construction on that phase is slated to begin no later than 18 months after the mill is completed and becomes operational in 2026.
Felix Schoeller Group has announced plans
to invest in a manufacturing operation for
release liners at the company’s Pulaski, New
York facility.
The planned investment will physically
expand the facility and also add new capabili-
ties. The new operation is designed to coat
both solventless and solvent based silicone
systems to best meet the requirements of
current and future customers.
“Building the new North American opera-
tion is a very logical step in our global Release
Liner strategy,” said Michael Szidat, CEO of
Felix Schoeller North America. “A manufac-
turing presence in our key North American
market will elevate us from an important
supplier to a true partner for our customers.
And expanding our technology to include
solvent coatings will allow our customers and
us to bring the Felix Schoeller performance
promise to a whole new set of markets and
applications.”
The new operation is expected to be
operational by 2023.
industry news
NORTH AMERICA
Pratt to Build New $400 Million Recycled Containerboard Mill in Kentucky
Ahlstrom-Munksjö to Temporarily Idle #8 PM at Rhinelander Mill in December
Felix Schoeller Plans Expansion of Release Liner Manufacturing in Pulaski, NY
© 2021 Buckman Laboratories International, Inc. All rights reserved.
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8 SEPTEMBER / OCTOBER 2021
industry news
Saica Group Plans to Invest $800 Million in U.S. Market
NORTH AMERICA
Pactiv Evergreen to Exit Coated Groundwood Paper Business
Greif, Inc. announced that it is expanding its CorrChoice – Concord sheet feeder operations in North Carolina. The company plans to acquire and install an Engico Jumbo Flexo Folder Gluer from Haire Group by the spring of 2022. The three color, 188" machine, which converts corrugated scored sheets into boxes, offers flexibility with 66" and 99" die cut cylinders and will be the third jumbo press in Greif’s CorrChoice sheet feeder network. “This investment enables Greif to continue its growth with new and existing strategic customers throughout the southeastern United States while enhancing customer service through diminished lead times,” the company said. Greif noted that the expansion is also expected to create up to 30 new jobs in Cabarrus County where the CorrChoice – Concord sheet feeder is located.
Spain’s Saica Group announced that it will be investing $800 million in the U.S. market, grow-ing through strategic acquisitions or new plant construction, during the next five years. This growth follows last year’s announcement of Saica’s first U.S. corrugated plant in Hamilton, Ohio, scheduled to open in early 2022. The plans were unveiled as part of the company’s “Saica 2025” strategic plan. “The journey to the U.S. market has not been an easy road, but we are con-vinced that we can provide products that will differentiate us in a crowded mar-ket,” said Saica Group President Ramón Alejandro. “We have been encouraged
by the tremendous support we’ve received as we began work on our plant in Hamilton, Ohio.” When open, the Hamilton Saica plant will occupy a newly-built 300,000 square-foot facility and will
include manufacturing, converting and production areas, along with a warehouse and office space. “We believe our extensive knowledge of low-weight recycled paper production along with the increased demand for cartons makes this a great time to come to the U.S. market,” Alejandro added. Saica’s investment will also bring approx- imately 500 jobs to the market. Specific growth plans are still being determined.
Pactiv Evergreen on July 28 announced that it has made the difficult decision to exit the coated groundwood paper business. As a result, the company will permanently cease production of coated groundwood paper at its Pine Bluff, Arkansas, location. Pactiv Evergreen said it will continue to strategically invest in the Pine Bluff mill, which will remain an essential facility in the Pactiv Evergreen operations network, serving the fiber-based beverage packaging market. “With the decline in the coated ground-wood market, our decision to exit this busi-ness enables us to re-invest resources into our strategic core competency of liquid packag-ing board as well as other more profitable segments across the enterprise,” said Mike
King, CEO. “Pactiv Evergreen will continue to employ more than 650 employees at the Pine Bluff mill, where liquid packaging board and extrusion manufacturing will remain.” Pactiv Evergreen noted that it will work directly with its coated groundwood customers to meet their product needs and support their
transition to new suppliers until production ends in Q4. The company expects to complete the closure by October 31, 2021, with ship-ments continuing until inventory is depleted. In a press release, Pactiv Evergreen said, “We are committed to helping support our team members during this difficult time. This decision is not reflective of the hard work and dedication of our team members nor the performance of the mill, but the reality of the coated publications business outlook. The Company thanks its hard-working team members for their many contributions. We also thank our long-term customers for their loyalty and understanding of this decision and are committed to working with them during this transition.”
Greif to Invest $10 Million in CorrChoice – Concord Sheet Feeder Operation in NC
10 SEPTEMBER / OCTOBER 2021
The Government of Saskatchewan has
approved timber allocations to support the
restart of Paper Excellence’s pulp mill in
Prince Albert, Saskatchewan, Canada.
“One of the key goals of Saskatchewan’s
Growth Plan is to increase forestry product
sales and exports and create more forestry-
related jobs in the province,” said Energy and
Resources Minister, Bronwyn Eyre. “The restart
of the Paper Excellence pulp mill is expected
to create over 1,650 direct and indirect jobs,
while enhancing northern and Indigenous eco-
nomic and labor development opportunities
within our world-class forestry sector.”
“The reopening of the pulp mill in Prince
Albert is welcome news for Saskatchewan’s
sustainable forestry sector,” said Environment
Minister, Warren Kaeding. “The facility will
play an important role in making the most
effective use of Saskatchewan’s forest resources,
including utilizing chips and other smaller
pieces of wood from sawmill production.”
With the $550 million capital investment
by Paper Excellence to refurbish and upgrade
the facility, the mill capacity will be 350,000
tonnes of Northern Bleached Softwood Kraft
(NBSK) pulp annually, requiring approxi-
mately 1,800,000 m3 of softwood fibre. The
Government of Saskatchewan is allocating
the timber through the Ministry of Energy
and Resources under The Forest Resources
Management Act. The province is allocating
the majority of the timber required for this
project, while the remaining balance will
be secured by the company through com-
mercial agreements negotiated with other
mills, Indigenous timber allocation holders
and private landowners.
The Government of Saskatchewan noted
that in 2020 more than $1.1 billion worth of
Saskatchewan forest products were sold —
an almost 30 percent increase over the
previous year.
industry news
NORTH AMERICA
Timber Allocations Approved for Restart of Pulp Mill in Prince Albert
Phoenix Paper has finished a $5 million recommissioning project for the pulp dryer at the company’s pulp and paper mill in Wickliffe, Kentucky. The addition of the pulp dryer will allow the mill to more efficiently operate the back end of the mill, as well as add a secondary product of baled pulp, the company said. According to Phoenix Paper, the project was complex, upgrading former equipment and raising the roof of the building to accom-modate the newer standard size of rail cars. The project was completed on time, on budget, with zero injuries. Phoenix Paper’s first shipment of baled pulp left the mill in four railcars during the first week of September.
New York-based Jamestown Container Com-
panies at the end of August announced the
acquisition of Cattaraugus Container, Inc.,
a converted paper product manufacturing
company in Franklinville, NY.
Terms of the deal were not disclosed.
“This purchase provides Jamestown
Container Companies with an immediate
growth opportunity in Western New York,”
explained Joseph R. Palmeri, Vice President
and Chief Operating Officer of Jamestown
Container. “We constantly look for ways to
strengthen our company’s position in the
markets we serve, opportunities that
support our long-term growth strategy to
focus on core competencies, minimize
the impact of rising costs, and maximize
customer, employee and shareholder value.”
With the acquisit ion complete,
Cattaraugus Container will operate as
a division of Jamestown Container
Companies in their current Franklinville,
NY location. In addition, Jamestown Con-
tainer plans to retain the entire Cattaraugus
Container workforce.
Phoenix Paper Completes Recommissioning Project for Pulp Dryer
Jamestown Container Companies Acquires Cattaraugus Container
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12 SEPTEMBER / OCTOBER 2021
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Smurfit Kappa has announced it is investing $22 million to expand its corrugated plant in Culiacan, North-West Mexico. The invest-ment will modernize and expand the plant, with the installation of high-tech machinery and the construction of a new 10,900m2 building that will include a new corrugator and an automatic Rotary Die Cutter that will be fully operational by the end of 2021. The facility will produce corrugated
boxes made with a moisture barrier that helps resist condensation. The project enables the Culiacan plant to match the fast-growing demand for
sustainable packaging solutions from agri-culture and fresh produce customers. “This investment will enable us to meet the increasing demand for innovative and sustainable packaging solutions not only in the region but also across Mexico,” said Juan G. Castaneda, CEO of Smurfit Kappa The Americas. “We have a strong customer base including some of the largest agricultural producers and FMCG companies in Mexico.”
industry newsMEXICO
Smurfit Kappa to Invest $22 Million in Its Corrugated Plant in Culiacan, Mexico
SOUTH AMERICA
Klabin Investing R$40 Million in Barrier Coating Project at Monte Alegre Mill
Klabin is investing R$40 million in dispersible barrier technology at its Monte Alegre paper mill in Paraná, Brazil, which will allow for the on-site application of sustainable barrier coatings to paperboard produced at the mill. The technology and machine modern-ization, which offers barrier properties for water, water vapor and grease will
retain original recycling and composting characteristics of paper, while offering a wider range of sustainable alternatives to the options currently available. The investment will be used to modernize a coating machine at the Monte Alegre Unit, whose annual production capacity will be increased to up to 60,000 tons. Flávio Deganutti,
Paper Director at Klabin, explained, “The invest-ment in modernizing this machine expands the markets that we can serve, which include chilled/frozen foods (pizzas, nuggets, hamburg-ers, meat, fish, sausages), industrial foods (pro-teins, broth, cookies), detergent powder, paper cups and more sophisticated solutions for liquid foods, all this on a larger scale.”
13SEPTEMBER / OCTOBER 2021
A top priority in the paper industry is improving the reliability of mechanical rotating equipment. Regarding low-speed couplings (typically connecting gearbox to roll), many options can greatly reduce operating costs and improve reliability. Below is an overview of three types.
Flexible Gear Couplings for Floating Shaft Assemblies
Gear couplings are used widely in the paper industry. These couplings can be reliable if proper maintenance and installations are performed.
Pros:• Can fit in very short DBSE (distance between
shaft ends) applications
• Are widely available
Cons:• Must be frequently greased
• Give little warning of imminent failure
• Require good alignments to ensure long life
For high-speed applications, a problem often arises where these couplings cannot be inspected. This is typically due to a short gearbox or motor shaft preventing movement of the geared sleeve so that wear cannot be inspected on the internal teeth. A simple solution for this would be implementing the Mi Mill Services Ultimate Coupling (Figure 1).
This coupling has these unique attributes:
• Large maximum bore capacity
• Split removable seal ring (allows removal of sleeve in both directions)
• Nitro-oxidized components
• Full-length sleeve teeth with high travel capacity
• Puller holes in flex hubs are an Ultimate Coupling standard
• Special grease channel porting allowing grease to distribute to both sides of teeth while installed
• AGMA (American Gear Manufacturers Association) or metric pattern options are available to couple to all other manufacturers’ rigid and flex halves
These are also a great fit for refiner applications requiring a removable seal ring.
Universal (Cardan) Shaft Assemblies
Universal driveshafts are another common type used widely in the paper industry. They are very reliable with proper implementation and maintenance performed.
Pros:• Flexible lengths due to slide section
• Ample warning of failure
• Flexible alignments (0–15 degrees)
Cons:• Frequent need for greasing
• Limited, short DBSE applications
In the paper industry, where electric motor prime movers are prominent, a universal driveshaft can be installed in almost all positions. A common misunderstanding is that the driveshaft must have a three-degree operating angle. However, a theoretical zero-degree operating angle can have great results. Mi Mill Services can analyze for optimum driveshaft sizing to address common oversizing problems and design a solution.
Disc Coupling Shaft Assemblies
Disc couplings are a popular upgrade choice in the paper industry. They have no backlash and are maintenance-free. When properly implemented, a very long service life can be expected.
Pros:• Maintenance-free
• No backlash
• Visual inspection
Cons:• Critical alignment and length
These couplings have very little acceptability of length change, which sometimes makes installation very difficult. A solution is a disc coupling assembly with built-in splined length compensation. Mi Mill Services specializes in these units and has provided such solutions to many customers.
A certified mechanical engineer, Frank Mathews is the branch manager of Motion’s Mill Services and has ten years’ experience with driveshafts and their applications. For more information, visit Motion.com/paperage or Mi Mill Services’ webpage (motionind.biz/3gjIZPb).
The High Points of Low Speed An overview of three low-speed coupling types common in the paper industryBy Frank Mathews, Motion
sponsored contentsponsored content
Figure 1. The Mi Mill Services Ultimate Coupling features large maximum bore capacity.
14 SEPTEMBER / OCTOBER 2021
Metsä Fibre said that the Kemi bioproduct mill project in Finland is progressing accord-ing to plan and the mill’s foundation stone was laid on September 13. The foundation stone placed in the fiber line area of the new mill by Ismo Nousiainen, CEO of Metsä Fibre; Jari-Pekka Johansson, Project Director of the Kemi bioproduct mill project; and Mika Vuoti, the on-site contact person. Totaling EUR 1.6 billion, the investment in Metsä Group’s Kemi bioproduct mill is the largest in the history of the Finnish forest industry. The bioproduct mill project has a high degree of Finnish origin, approximately 70 percent. “The impact of this large-scale industrial investment is significant. The Kemi bioproduct mill will increase Finland’s annual exports by around EUR 0.5 billion and its annual
positive income effect through the value of the wood raw mate-rial and the purchasing of Finnish labor is likewise roughly EUR 0.5 billion,” Nousiainen said. Johansson explained, “We are proceeding purposefully towards the start-up of the new mill in the third quarter of 2023. At the moment, the project is focused on earthworks and this autumn, we will be moving on to the first equipment installations. Some 450 people are currently working on the site.” Operating entirely without fossil fuels, the Kemi bioproduct mill will produce annu-ally some 1.5 million tonnes of softwood and hardwood pulp, as well as many other
bioproducts. It will also produce 2.0 TWh of renewable energy a year, which is equal to approximately 2.5% of Finland’s total annual electricity production.
industry news
EUROPE
Metsä Fibre Lays Foundation Stone for Kemi Bioproduct Mill
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(l-r) Jari-Pekka Johansson, Project Director of the Kemi bio-product mill project; Ismo Nousiainen, CEO of Metsä Fibre; and Mika Vuoti, on-site contact person.
SEPTEMBER / OCTOBER 2021 15
industry news
EUROPE
Thimm Invests EUR 1.6 Million in Its Alzey Corrugated Plant
Thimm announced that it has invested EUR 1.6 million in its Alzey corrugated cardboard plant located in Rhineland-Palatinate, Ger-many. The investment includes a compre-hensive expansion of the corrugator and the installation of a new conveyor system. According to Thimm, the modernization project allows the Alzey plant to produce cor-rugated F-flute, which, in Europe, is typically used for specialty packaging, point-of-purchase displays, jewelry and cosmetic packages, and shoe boxes. This modernization means that Thimm is now able to produce F-flute in Germany for the first time. Additional investments in process auto-mation at Alzey are planned for the fourth quarter of 2021, Thimm said. A large part of the Alzey investment package, namely the conversion work on the corrugator, began in May — the previous unit has been replaced by the more modern “Modul
Facer®” corrugating roll module from BHS Corrugated. This has enabled the maximum production speed of corrugated cardboard to be increased to 350 metres per minute. The investment also secures the supply of E, F, B, C and T-flute to the other Thimm plants nearby, along with their combinations as double wall corrugated cardboard. Various other peripheral and renovation measures were also carried out along with some machine upgrades. The project took place during ongoing operation.
VIETNAM
SCGP to Build New Packaging Paper Production Base in Northern Vietnam
Thailand-based SCGP announced that it is moving ahead with an expansion plan to build a new production complex in Vinh Phuc in northern Vietnam for the production of packaging paper. The total investment amounts to 8,133 billion VND (approx. US$353,500.00). In a press release, SCGP said,“In order to grow alongside other industries inside Vietnam and to meet increasing demands for packaging products, SCGP has decided to expand through Vina Kraft Paper by building a new major complex in Vinh Phuc — a strategically important area in the northern part of the coun-try, as well as adding packaging paper production facilities to boost capacity by about 370,000 tons a year.”
continued on page 16
16 SEPTEMBER / OCTOBER 2021
industry news
SCGP said the investment is currently under Environmental Impact Assessment (EIA) process and expects the plan to be completed and commercial production to begin in early 2024. SCGP noted that Vietnam has strong domestic consumption and is an impor-tant export base in the region, a big draw for multinational companies to invest their operations there, especially to the northern part of the country. The demand of packaging paper and related packag-ing products in Vietnam is expected to increase at approximately 6-7% per year during 2021-2024 (source: Frost & Sullivan). Mr. Wichan Jitpukdee, Chief Executive Officer, SCGP, commented, “Driven by SCGP's existing business model in Vietnam that consists of broad horizontal offerings and deep vertical integration primarily located in the south of Vietnam, our new investment in this production complex will allow us to pursue growth opportunities in the north of Vietnam and the south of China.”
Segezha Group is implementing a large-scale investment project to build a new paper machine at its Sokol Pulp and Paper Mill in the town of Sokol, Vologda Oblast, Russia. The total investment is over RUB 11 billion (approx. US $151,000). According to Segezha Group, the pro-ductive capacity will quadruple — from 20,000 tpy to 80,000 tpy. The full range of equipment will be designed and supplied by the German company Bellmer. The new machine will be 135 meters long and will be built in a new hall next to the existing production facility. The new PM will be designed to ensure sustainability and a closed-loop production concept. A modern two-level wastewater treatment system will be installed. The implementation of the project will help significantly increase production efficiency and make full use of pulp
cooking facilities, the company noted. The new PM will quickly switch between greaseproof and sack paper manufacturing, which will allow the mill to effectively meet consumer requests. “The fast food industry, restaurants, coffee houses and bakeries are the main consumers of greaseproof paper. They account for more than 90% of its con-sumption,” said Alexander Kharitonov, VP for Commerce at Segezha Group. "At the same time, there is growing concern about the environment. People are trying to protect nature and choose biodegrad-able, environmentally friendly greaseproof paper and packaging whenever it is possible. Therefore, we believe that capacity expan-sion is an optimal response to the consumer demands and the market transformation we are observing.” Commissioning of the new paper machine is scheduled for 2023.
continued from page 15RUSSIA
Segezha Group to Install New Paper Machine at Its Sokol Mill
17SEPTEMBER / OCTOBER 2021
industry news
Kadant Inc. in late-August completed its acquisition of Balemaster for $54 million in cash, subject to certain customary adjustments. Balemaster is a leading U.S. manufacturer of horizontal balers and related equipment used primarily for recycling packaging waste at corrugated box plants and large retail and
distribution centers. The company’s revenue for the trailing twelve months ended June 30, 2021 was approximately $22 million. “Our acquisition of Balemaster expands our presence in the secondary material processing sector and creates new opportu-nities for leveraging our high-performance balers produced in Europe,” said Jeffrey L.
Powell, President and CEO of Kadant Inc. “The company is a market leader in North America and its strong aftermarket business fits well with Kadant. We are excited to welcome the employees of Balemaster to the Kadant family.” Balemaster will become part of Kadant’s Material Handling reporting segment.
Kadant Acquires Leading U.S. Baler Manufacturer for $54 Million
Voith announced that it has received an order from Shandong Huatai Paper to rebuild and modernize PM 11 located in the eastern Chinese province of Shandong. The project will convert PM 11's production from news-print to high-quality graphic paper. After the rebuild, the production line will have a significantly increased annual capacity of 520,000 tons at a design speed
of 1,800 m/min. The scope of Voith's supply includes a new MasterJet Pro G headbox, an upgrade of the forming section similar to the DuoFormer concept, and new Pro-Release+ HighEnd boxes in the pre-dryer section for improved web stability at high speeds. In addition, a SpeedSizer AT with its smooth
film application will ensure even and high-quality paper profiles, and in the after-dryer section, the CombiDuoRun drying concept will be installed. The scope of supply also includes new automation solutions to efficiently upgrade the existing control systems. Start-up of the rebuilt paper machine is expected in 2023.
INDUSTRY SUPPLIERS
Voith to Supply Shandong Huatai Paper with Machine Conversion Project
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Valmet and CMPC have signed a letter of intent for Valmet to deliver key technology for the BioCMPC project. The target of the project is to increase the production capac-ity of the Guaíba pulp mill’s line 2 from 1.5 million ADt/y (air dry tonnes per year) to 1.85 million ADt/y. The modernization is expected to start operation in the fourth quarter of 2023. Valmet and CMPC plan to finalize the contract during October 2021. This expansion project, BioCMPC, targets both to increase the production capacity of the Guaíba mill and also improve the envi-ronmental performance with for example increased production of renewable electricity and minimized water usage in pulp produc-tion process. “With this project we will continue deliv-ering the best technology available combined
with leading automation and industrial internet solutions for efficient and even more sustainable pulp production,” said Bertel Karlstedt, Business Line President, Pulp & Energy, Valmet. “This delivery will feature our latest technology to lower water usage, reduce emissions and eliminate odorous gases. Our experts will support optimizing the mill performance both onsite and remotely.” Valmet’s delivery for the Guaíba pulp mill
line 2 modernization will include rebuild of the pulp drying, fiberline, evaporation and white liquor plant, a new recovery boiler and new ash treatment, extended distrib-uted control system including advanced industrial internet features. The technology delivery is supported by spare parts packages. The upgraded line is optimized for high reliability and performance with low environmental impact. CMPC produces wood, pulp, packaging products, paper, tissue, and personal care products from certified plantations. The company has over 641,000 hectares of forest plantations, mainly pine and eucalyp-tus, located in Chile, Brazil and Argentina. CMPC Pulp SpA operates 4 production lines in Chile and 2 in Brazil, with total annual production capacity of approximately 4.1 million metric tons of pulp.
industry news
INDUSTRY SUPPLIERS
Valmet and CMPC Sign Letter of Intent for Modernization of Guaíba Pulp Mill
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MADE IN THE
U S A
19SEPTEMBER / OCTOBER 2021
ABB and Södra have entered a long-
term, strategic partnership to co-develop
a roadmap to drive new levels of effi-
ciency, engagement and digitalization
across Södra's enterprise to ultimately
define the next generation mill.
The contract, effective from
September 2021, is designed as a con-
tinuous engagement model, with ongo-
ing reviews of short and long-term goals
to ensure the digitalization of Södra's
operations. Södra's intent is to build its
digital capabilities and increase efficiency,
sustainability and circular resource
utilization throughout the value chain.
The scope will be jointly defined
using the full industrial digitalization
technology stack based on the founda-
tion of ABB’s Ability™ portfolio, including:
• ABB’s 800xA Distributed Control
System (DCS), an integration platform
with connectivity to enterprise and
plant systems providing a collab-
orative environment where real-time
decision making is a reality.
• ABB’s Pulp and Paper digital solu-
tions which supply advanced software
applications that enable modern mills
to maximize visibility, reliability,
productivity and energy efficiency.
• ABB Ability™ Genix Industrial
Analytics and AI Suite, a platform
with the ability to collate and contex-
tualize data from diverse sources.
“ABB’s collaborative approach, global
technology leadership and digital expertise
was key to our decision to choose them
as our partner,” said Magnus Björkman,
President of Södra Cell Business Area.
“Their foresight of what we want to
achieve through this digitalization project
will bring new levels of efficiency in
our operations and create an even more
desirable workplace of continuous
learning for this and the next generation
of workers.”
industry news
INDUSTRY SUPPLIERS
ABB to Supply Södra with Industrial Digitalization Technology across Its Mills
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20 SEPTEMBER / OCTOBER 2021
sustainability matters
Advancing the Circular Economy: One Innovation at a TimeBy Heidi Brock, President and CEO, American Forest & Paper Association
When someone uses the phrase “full circle,” you might immediately envision
a loop or cycle. It’s a simple concept to visualize. But when you hear the words “cir-cular economy,” especially for the first time, it may not be so easy to imagine. While we all know what these two words mean separately, what do the two words together imply? By definition, The Ellen MacArthur Foundation describes the circular econ-omy as an economy “that is restorative and regenerative by intention [and] by design.” Based on these principles, the circular economy aims to eliminate waste, keep products and materials in use, and regenerate natural systems. So, how exactly does the paper and wood products industry contribute to the circular economy? AF&PA members are dedicated to advancing industry sustainability and the circular economy. We manufac-ture paper and wood products that are among the most used, necessary and sustainable items for everyday living. Daily reminders, like cereal boxes and facial tissues, are proof of our industry’s innovative and sustainable products.
Products that touch lives in homes, schools and businesses from newspapers, notepads, to paper towels and milk cartons, along with our trusted boxes to protect, ship and deliver goods.
As paper and wood products help us complete life’s daily tasks, they also can be tools or examples to help educate others on how these products are essen-tial to the circular economy. Our members are constantly innovat-ing through manufacturing processes at mills across the United States. Processes that will help the future design of prod-ucts and packaging, making them more recyclable and sustainable. We also look to maximize the use of our renewable resources, using every part of the tree, to develop products and support the industry’s manufactur-ing processes and beyond. Several examples come from recent AF&PA Sustainability Award winners. Our awards help recognize projects that members accomplished while showcasing
the circular economy at work. And soon, we will announce this year’s Sustainability Awards. In 2020, one of our winners was WestRock. The company designed and developed a proprietary fiber-based packaging solution, called the Pak On Demand™ Pouch System. Using an innovative format, the system creates right-sized fiber-based pouches that are 100-percent-curbside recyclable. Another principle our members actively work toward is reducing waste. Last year, Sappi North America was recognized for its Caustic Reclaim and Reuse project. Their Somerset mill in Skowhegan, Maine reduced both the amount of purchased caustic by 660 tons per year and reduced its overall mill water use by 12,000 gallons per day.
By definition, The Ellen MacArthur
Foundation describes the circular economy
as an economy “that is restorative and regenerative by intention [and]
by design.”
21SEPTEMBER / OCTOBER 2021
The reduction process method has surpassed the industry standard, which helps the Somerset mill meet its environmental ambitions. As water is an essential part of the paper-making process, our industry actively works to invest in more efficient technologies to improve water stewardship. AF&PA members continuously work to do more with less. On average, about two-thirds of the energy used at paper and wood products mills is generated from our renewable bioenergy — primarily residuals from the manufac-turing process. Our sustainable use of renewable bioenergy to power our mills provides significant greenhouse gas reduction benefits. It also promotes the efficient use of renewables and allows us to utilize a renewable bioenergy source to produce sustainable products. Whether it is a goal or policy issue, AF&PA and our members are commit-ted leaders in the circular economy. Most recently, that work has included testifying on Capitol Hill. In September, AF&PA addressed the U.S. Senate Committee on Environment and Public Works, highlighting the essential and sustainable nature of our products, and paper recycling’s success. Earlier this year, we also released The Design Guidance for Recyclability for Paper-based Packaging. This voluntary guide provides data for packaging designers and consumer brands to better understand how non-fiber elements, such as coatings and additives, affect the recyclability of paper-based packaging in paper mills. Together, we have a long-standing and proven commitment to sustainability and the broader circular economy. We are leading by example and demon-strating how our leadership can reach new possibilities.
I encourage you to join us in this industry mission and follow along as we announce a new class of Sustainability Award winners later this month.
About AF&PA
The American Forest & Paper Association (AF&PA) serves to advance U.S. paper and wood products manufacturers through fact-based public policy and
marketplace advocacy. The forest products industry is circular in nature. AF&PA member companies make essential products from renewable and recyclable resources, generate renewable bioenergy and are committed to contin-uous improvement through the industry’s sustainability initiative – Better Practices, Better Planet 2030: Sustainable Products for a Sustainable Future.
sustainability matters
22 SEPTEMBER / OCTOBER 2021
suzano
Based in São Paulo, Brazil, Suzano is one of the world’s largest integrated pulp and paper producers. With ten
mills and the joint operation Veracel, the company has an annual installed capacity of 10.9 million tons of market pulp and 1.4 million tons of paper. Its product portfolio includes coated and uncoated printing and writing paper, paperboard, tissue, market pulp and fluff pulp. All of Suzano’s mills are either close to ocean ports or connected by railway. The company exports pulp from three ports in Brazil with twelve fully dedi-cated vessels serving 86 countries. In addition, Suzano has plantations covering 1.3 million hectares of certi-fied land.
Ever Evolving
Today’s Suzano is the result of 97 years of evolution that started when Leon Feffer, a Ukrainian immigrant, arrived in Brazil in 1924 and shortly thereafter obtained approval for his individual firm, marking the creation of Suzano Papel e Celulose (“Suzano”). Seventeen
years later, Leon’s first paper mill began operations in the Ipiranga district of São Paulo. That first mill used pine as its pri-mary raw material for the first 10 or so years of operation. During that time, Leon’s son Max conducted research for an alternative raw material to substitute pine, and the company acquired a mill in Suzano (a municipality in São Paulo) to carry out tests. In 1956, the mill began producing pulp from eucalyptus — at that time, a revolutionary develop-ment in the pulp industry in Brazil and worldwide. In 1961, Suzano became the first company in the world to produce pulp and paper using 100% eucalyptus fiber on an industrial scale. The company had just expanded its production line by acquiring its current Rio Verde paper mill in São Paulo. Over the next 30 years, Suzano con-tinued to develop its pulp, along with a range of improved paper grades. In 2004, Suzano and Votorantim Celulose e Papel (VCP) formed a con-sortium and acquired Ripasa, which at that time was among the largest
pulp, paper and board producers in Brazil. The operation came with four production units in São Paulo, as well as vast eucalyptus plantations. Suzano and VCP each held a 50% stake in the venture until 2011 when Suzano acquired all of the shares. Today, Ripasa is Suzano’s Limeira Unit. In December of 2013, Suzano start-ed-up its newly constructed pulp mill in the city of Imperatriz in the state of Maranhão. A few months later, the Imperatriz mill shipped its first order of pulp to the United States. Today, the Imperatriz Unit has the annual capacity to produce 1.590 million tons of market pulp, 60,000 tons of integrated pulp and 60,000 tons of tissue. In 2015, initial production of a new bleached eucalyptus kraft fluff pulp began at the company’s Suzano Unit. Known as Eucafluff, the high quality fluff pulp is engineered for the production of sanitary pads and disposable diapers. A year after its commercial scale production began, Suzano launched its first brands of toilet paper — Max Pure and Mimmo. Suzano followed up its entry into the tissue segment with the acquisition
Inspired By TreesThrough nearly 100 years, Suzano has evolved to become the largest producer of pulp in the world and a leading manufacturer of paper in Latin America, and the Brazilian forest products company continues to plant its future with trees and sustainable business operations.
By John O’Brien, Managing Editor
23SEPTEMBER / OCTOBER 2021
suzano
Pulp and Paper Mills(annual capacity in tons)
Suzano, São PauloIntegrated Pulp (450,000)
Market Pulp (70,000)
Fluff Pulp (100,000)
Paper (550,000)
Limeira, São PauloIntegrated Pulp (290,000)
Market Pulp (400,000)
Paper (400,000)
Jacareí, São PauloPulp (1.1 million)
Rio Verde, São PauloPrinting & Writing Paper (50,000)
Imperatriz, MaranhãoIntegrated Pulp (60,000)
Market Pulp (1.59 million)
Tissue Production (60,000)
Aracruz, Espírito SantoPulp (2.34 million)
Três Lagoas, Mato Grosso do SulPulp (3.25 million)
Belém, Pará and Maracanaú, CearáTissue (84,500)
Mucuri, BahiaIntegrated Pulp (200,000)
Market Pulp (1.48 million)
Printing & Writing Paper (250,000)
Tissue (60,000)
*Veracel in BahiaPulp (560,000)
* Veracel is a joint operation between Suzano (50%) and Stora Enso (50%) with a total annual capacity of 1.12 million tons.
of Brazil’s Facepa (Fábrica de Papel da Amazônia S.A.) in March of 2018. The deal included Facepa’s tissue mills in Belém, Pará and Fortaleza, Ceará, with a combined annual capacity of 170,000 tons of tissue paper. With the acquisition, Suzano became the third largest manu-facturer of sanitary tissue papers in Brazil, with a prominent position in the country’s North and Northeast regions.
Merger with Fibria
The biggest deal in Suzano’s history, however, was announced in March of 2018 when Brazil’s largest pulp producers, Suzano Papel E Celulose and Fibria Cellulose, announced that the controlling shareholders of Suzano Holding S.A. and Fibria Celulose S.A. agreed to a combination of the two companies in a cash and stock merger. The last phase of the transaction was finalized on January 14, 2019 when Suzano Papel E Celulose paid R$27.8 billion to Fibria’s shareholders, who in turn became shareholders in Suzano, the company’s new trade name. “We have successfully realized a dream,” said Walter Schalka, CEO of Suzano. “The journey on which we now embark is driven by the aspiration to play a leading role in the advancement of society, to be a reference in the
sustainable use of renewable resources
and, consequently, to help build a better
world, today and tomorrow.”
The combination created the largest
producer of pulp in the world.
Cerrado Project
Most recently, Suzano on May 12, 2021
announced the construction of a new
pulp mill with an annual production
capacity of 2.3 million tons. The $2.8
billion project is one of the largest
private-sector investments currently
under development in Brazil.
The eucalyptus pulp mill will be
built in the municipality of Ribas do
Rio Pardo, in the state of Mato Grosso
do Sul, with production scheduled to
begin Q1 2024. The initiative, called the
“Cerrado Project”, will increase Suzano’s
current pulp production capacity of
10.9 million tons by approximately 20%.
Beyond the production of pulp, the
new mill will increase the supply of
renewable energy in Brazil. The plant
will have the capacity to sell approxi-
mately 180 MW of surplus energy to
Brazil’s power grid and is set to become
Brazil’s first fossil fuel-free pulp mill,
representing a new milestone in eco-
efficiency and sustainability for the
industry and region.
Suzano has an annual installed capacity of 10.9 million tons of market pulp.
24 SEPTEMBER / OCTOBER 2021
Once completed, the project will be the world’s largest mill with a single eucalyptus pulp production line and offer some 3,000 job opportunities.
Sustainability at the Forefront
David Feffer, Chairman of the Board of Directors of Suzano, (grandson of company founder Leon Feffer and son of Max Feffer) emphasized that Suzano will continue to contribute to help Brazil assume its global leading role on environment and bioeconomy. “We believe that part of this task should be taken on by the private sector, and the planted tree sector is one of the most relevant on this front,” Feffer explained. “At Suzano, we are committed to a series of long-term goals, such as replacing 10 million tons of plastics and petroleum products with products from renewable sources by 2030. It is with challenging goals like this, courage and a robust plan to face them, that we will continue working to become part of the solution to the great challenges of the 21st century,” Feffer added.
Suzano’s sustainability strategy pri-orities include:
Emissions – Reduce GHG emissions intensity (tCO2e/ton produced) by 15% (emissions scopes 1 and 2) by 2030.
Become Even More Climate Positive – Remove an additional 40 million tons of net carbon (carbon capture minus emissions scopes 1, 2 and 3) by 2030.
Industrial Waste – Reduce by 70% the industrial waste sent to landfills.
Energy – Increase renewable energy exports by 50%.
Water (Forestry) – Increase water avail-ability in 100% of critical watersheds and (Industrial): reduce water with-drawal intensity by 15%.
Replace Plastics and Petroleum
Derivatives – Offer 10 million tons of products from renewable sources by 2030.
Mitigate the Problem of Income
Inequality – Lift 200,000 people over the poverty threshold in our areas of influence by 2030.
Education – Enhance the Brazilian Basic Education Development Index (IDEB) by 40% in our areas of influence by 2030.
Diversity and Inclusion:
• have 30% women and 30% blacks in leadership positions (managers, direc-tors and Board) by 2025;
• ensure 100% accessibility and zero prej-udice, witnessed or experienced, against people with disabilities by 2025;
• achieve 100% inclusive environment and zero prejudice, witnessed or experi-enced, against LGBTI+ by 2025.
Conclusion
In December of 2020, Suzano announced its new Organizational Purpose, “Renewing life inspired by trees.” According to the company, the concept is the result of over a year of work that involved input from some 3,500 people, including employees and various external stakeholders. “We see the need for a new move-ment to regenerate and oxygenate the planet,” Mr. Schalka said. “And we see in trees the best response to the con-cerns of today’s world, which is worried about climate change, the depletion of natural resources, the loss of biodiversity and growing social inequality.”
suzano
Suzano exports pulp from three ports in Brazil with twelve fully dedicated vessels serving 86 countries.
26 SEPTEMBER / OCTOBER 2021
automated guided vehicles
Automation in the pulp
and paper industry has
traditionally concen-
trated on the produc-
tion process, improving
quality, reducing waste and increasing
productivity. Adopting a more holistic
approach, attention is now also being
paid to in-house logistics and the way
product is handled after it leaves the
paper machine. The in-house transportation and warehousing of paper rolls, pallets of sheet products and pulp bales are 24/7 operations where automated logistics technology can offer great opportuni-ties for increased efficiency and safety. The Automated Guided Vehicle (AGV) is a key tool in a modern Warehouse Management System (WMS) to maxi-mize benefits of higher throughput, precision and safety. The modern AGV is more flexible and versatile than ever before and offers scalable solutions for automated logistics deployment at both large and smaller enterprises.
When to Consider an AGV Solution?
Even with the best warehouse manage-ment systems, manually operated forklift transportation is still a bottleneck to optimal efficiency.
Rolls and pallets are lost or misplaced
Wrong rolls delivered to secondary processing machines
Careless forklift operations causing damage to both product and equipment
Falling rolls and pallets due to improper or faulty stacking
Inability to provide cost effective 24/7 internal transport expertise
All cause interruptions in subsequent finishing and warehouse operations, increasing processing machine idle time, outages to the paper machine and ultimately compromising customer delivery schedule.
The Modern AGV
Until recently, AGVs were considered useful in mainly large, specialized areas of manufacturing and warehousing.
AGVs were expensively customized, requiring very specific and costly guid-ance systems. For smaller operations, the return on investment was difficult to justify. Today however, AGV tech-niques and capabilities make them more cost effective and more versatile than ever before. With the expansion of the interconnected factory and Internet of Things (IoT), AGV implementation is fast becoming a prerequisite to take full advantage of Industry 4.0 technology.
According to Kari Johansson, solu-
tions management director for Rocla
AGV Solutions, the AGV market is
growing and technology is developing
at the same pace. He notes that when
integration is seamless, customers can
combine different modules together
easily and reduce the high ICT cost that
integration may have had in the past.
“Sensor and navigation technology
development have helped, but the
biggest developments have happened in
software,” Johansson explained. “The AGV
industry must respond to the challenge
Today, automated guided vehicle techniques and capabilities make them more cost effective and more versatile than ever before.
An Insight to AGV Implementation in the Pulp and Paper Industry
27SEPTEMBER / OCTOBER 2021
Rolls or roll
SKUs for conver-ting, based on production order
1. Rolls and pallets
based on shipping order
2.
Quality control and broke roll
handling
Wrapping and label printing
ROLL AND PALLET PICKING
Sheet cutting
Staging Parent roll Winder and slitter
Load carrier
Ream wrapping
Packing, palletizing and pallet wrapping
Palletized SKUs Pallet stacker
Waste pallet/container handling within the process
Warehouse (unwrapped)
Warehouse (wrapped/palletized)
Sorting by SKU if required by simultaneous handling of multiple rollsRoll put-away
1.
2.
Order-based or SKU-based storing process
Warehouse strategy
picking process
3.
4.
Pallet picking,
according to shipping order
1. Case picking and mixed SKU pallet forming
Load forming according to shipping order
2.
3.
automated guided vehicles
of making systems easy and seamless to integrate to customers’ control systems. Rocla is developing this integration level, not only upwards to the enterprise resource planning system (ERP), manu-facturing execution system (MES) and the warehouse management system (WMS), but also horizontally between automation systems. Increased horizontal integration is certainly important in the future. It gives customers better tools.”
AGV Advantages
Implementation of an AGV fleet can have immediate bottom line advantages. Costs, unlike manual labor, are predict-able and relatively independent of local economic conditions. AGV solutions are scalable, with more units added as extra capacity or throughput needs are identified. Availability is 24/7, enabling repetitive tasks like order picking and load con- solidation to be undertaken with precision at night for immediate morning dispatch.
As soon as an item is transported by an AGV it is tracked, no more lost or misplaced products.
Increased secondary processing machine up-time with accurate and timely delivery of rolls.
No machine or product damage from manual truck impacts.
AGVs handle products gently and predictably to reduce waste.
Reliable on-time delivery improves scheduling capabilities and the efficiency of operations.
Improved housekeeping functions and lower inventory costs.
Increased safety with collision avoid-ance capabilities improving the safety of personnel.
AGVs eliminate access issues created by conveyors or cranes.
AGV solutions are flexible to changing production and product handling requirements. They can be full or semi-automated solutions according to specific needs.
AGV system costs are very predictable.
AGV system can be implemented without production stops.
CASE HISTORY 1. Coated Paper Mill (560,000 tpy) – Reel Transport
The Challenge. This mill averaged 2000 movements per day with manually operated trucks by 20 drivers on a 5 shift system. Problems encountered by the customer included damage to equip-ment by inexperienced drivers, product damage from reel clamps and reel falls
interfered with sheet cutter operation, lost reels not found by the driver in time and limited capacity causing flow prob-lems from the paper machine.
Solution. Rocla’s solution included 9 reel handling AGVs (including 2 with rotating clamps), automatic battery exchange, modification to existing conveyors (pick-up and delivery areas), Warehouse Management Software (WMS) and AGV supervisory system. Installation, commissioning and training of the mill’s personnel was included in the delivery.
Results. The mill remained operational during implementation which was per-formed in 8 phases over a 2-month period. After one year in operation the mill reported that the fully automated solution including reels pick-up, sheet cutters delivery and rewinders area delivery had met or exceeded all project targets. No clamp marks on reels (the target had been less than 3 sheets), no reel falls and all reels delivered to cutters on time as well as increased movement capacity to match paper machine production.
The AGVs required 30 minutes per shift from an operator working on other equip- ment and Rocla recommends preventive
Typical AGV applications within paper mill’s manufacturing and logistic processes.
28 SEPTEMBER / OCTOBER 2021
maintenance every 6 months or 1,000 hours of operation. A special feature of the WMS was a search capability of warehouse stock for “missing reels,” — in case a desired reel had not been
produced by the paper machine, the
system will seek an available alternative reel to complete an order. This feature was credited by the customer as a 1% productivity gain (+ 10 tpd). During the first year there were no accidents or risk situations.
CASE HISTORY 2. Printing Paper Mill
The Challenge. With around 1,000 different pallet sizes with varying heights, 2 to 4 pallets are stacked on top of each other in the warehouse. Key objectives for the customer were to achieve stable stacks and reduce costs.
Solution. Rocla’s solution included 3 AGVs and warehouse management system to handle unloading the con-veyor belts for wrapped sheet pallets, and transportation to the loading ramp used for both the internal and external trailer system.
Results. The capacity of the sheet department is now 35 pallets per hour, from the conveyor belt to the storage area and finally to the loading ramp. The AGV system is protected with safety installation ensuring no hazards for people and no collisions. The whole system is approved by the safety authority, which means that the system can run-independently without constant supervision from mill staff.
Steps to AGV Implementation
Audit Assessment of intralogistic needs and
feasibility study Solution for handling and warehousing
Maintenance process, life-cycle and spare part criticality assessments
Financial assessment
Solution Design Warehousing and staging strategy Intralogistics process design AGV system layout and route design Vehicle options adjustment Software integration plan
Implementation Integration to information systems
(e.g., Warehouse Management System) Interfacing with facility equipment Factory acceptance testing at Rocla Installation and commissioning onsite Site acceptance test
Maintenance and support
Usage-based and scheduled maintenance Software updates Onsite repairs Training of your logistics personnel
Monitoring, remote diagnostics and data analytics
Route and order optimization Increased capacity and automated
upkeep routines Equipment remote monitoring Service dashboard with real-time
operational monitoring Maintenance and availability statistics
Conclusion
Rocla AGVs are a modular design based on proven warehouse truck technology by Mitsubishi Logisnext Americas. This allows existing maintenance personnel and facilities to be utilized with a minimum of additional training and retooling. Sharing a common electrically driven tractor unit with automated battery exchange capability, customizable load handling modules from forks and roll conveyors to paper reel clamps cover most of the requirements for pulp bale, paper reel and sheet board transporta-tion applications. The typical lifetime of a Rocla AGV vehicle is 10 years, or up to 20 years with selected upgrades to control electronics. Rocla service agreements can cover all preventive maintenance needs with a suitable service level selected from basic support to guaran-teed availability.
For further information about AGV Implementation, contact: Brian Markison, Senior Director, AGV Sales, at: [email protected].
automated guided vehicles
AGV solutions are
scalable, with more
units added as
extra capacity or
through put needs
are identified.
29SEPTEMBER / OCTOBER 2021
classified
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index of advertisersCOMPANY PAGE WEBSITE
Buckman 7 www.buckman.comCR Meyer 12 crmeyer.comDienes 9 www.dienesusa.comEdwin X. Graf 29 [email protected] 19 www.enessco.comEssco 15 esscoincorporated.comFMW 14 www.fmw.co.atGE Steam Power 11 ge.com/steam-powerIndustrial Shredders 18 industrialshredders.comKaman Industrial Technologies 16 kamandirect.comMotion 13 motion.comMSC 31 msc.com/paper-forestryNationwide Boiler 21 www.nationwideboiler.comPapermachine Service Ind. 29 papermachine.comPapertech Inc. 2 www.papertech.caPENN Warehousing 25 www.pennwarehousing.comValmet 32 valmet.comVM5 Lighting 17 www.vm5lighting.comVoith 5 voith.com/paper
30 SEPTEMBER / OCTOBER 2021
Accounting for 25.09 million tonnes in 2021, the specialty papers market is dynamic and
will present multiple lucrative diversi-fication opportunities across the next five years. This includes delivering new grades that will allow companies to deliver on commitments to substitute away plastic in packaging; and niche industrial applications such as filtration, battery and electrical insulation papers. As a sector, specialty papers will see solid growth through the first half of the decade at a compound annual growth rate of 2.4%, driving demand to 28.26 million tonnes in 2026. Published by Smithers, The Future of Specialty Papers to 2026 market report quantifies historic, current and future demand for 46 specialty grades. It shows that the immediate challenge is reengaging with markets in the immediate wake of the Covid-19 disruption. Globally con-sumption of specialty papers declined by -1.6% (CAGR) across 2019-2021, but the pandemic’s impact was far from uniform. Demand for labelstocks and release papers increased as more consumers took to ordering goods online during lockdown. Several food contact grades — such as wax and parchment papers — also benefited from a surge in home baking and food preparation; other food packaging types saw increased sales linked to more take-outs and delivery of food from restaurants. Medical specialty papers use rose, as protective measures were implemented in hospitals and locations for Covid-testing and vaccination. These testing protocols meant that demand for labo-ratory papers remained positive and these will continue to see robust growth through to 2026.
Most other industrial segments saw a fall in demand as end-use industries closed or slowed production.Consumption of ticket papers fell by -16.4% over 2019-2020, as travel restrictions were implemented; and the wider use of contactless electrical payments saw check paper volumes fall by -8.8%. In contrast currency papers increased by 10.5% in 2020 — but this is very much a short-term phenomenon. It is not representative of more cash circulat-ing, but rather the understood tendency in times of economic uncertainty for consumers to hold hard currency. In 2021, Asia-Pacific is already the largest region for specialty papers, accounting for 42% of the global market. As the economic shock of 2020 sub-sides, paper manufacturers in China are ramping up production to feed booming domestic demand, as well as selling to export markets. This recovery and especially the spending power of a burgeoning local middle class will make Asia-Pacific the fastest growing region over the next five years. Growth in the mature markets of North America and Western Europe will be more flaccid. The medium-term outlook for packaging
papers — C1S, machine glazed, etc. — remains positive, especially where these are combined with the latest water-based coatings to provide a more recyclable alternative to flexible plastic packaging. Where these can deliver the neces-sary barriers to moisture, gas, oil and grease, they can substitute a recyclable monomaterial paper for plastic formats. These are innovations that brand owners will pay for, as they search for demon-strable ways to meet regulatory and sus-tainable corporate citizenship goals. The impact of Covid-19 on industrial segments will be temporary. As normality returns, and new government-backed infrastructure and house-building policies come on stream, demand for electrical — insulation, battery separator, cable — papers will rebound. Some of these will directly benefit from spending on new technologies, such as electric vehicles and supercapacitors for green energy storage. New home construction will also boost use of wallpaper and other décor papers, although this will be concentrated mostly in the less mature economies of Asia, the Middle East and Africa. Smithers’ analysis forecasts that the pre-pandemic trend for larger companies to expand their global footprint and enact savings through vertical integration by acquiring converting capacity will foster future M&A activity. This will increase pressure on smaller less diversi-fied specialty papermakers, even as they look to find their position in a market space reshaped by Covid-19.
Founded in 1925 and headquartered in Akron, Ohio, Smithers is a multinational pro-vider of testing, consulting, information, and compliance services. To learn more, visit: www.smithers.com.
market insight
Stability, Growth, Innovation on Horizon for Specialty Papers Market
In 2021, Asia-Pacific is already the largest region for specialty
papers, accounting for 42% of the global market.
Many mills lose productivity due to old equipment operating inefficiently or over capacity. Changing priorities can make it difficult to stay on top of manufacturer recommendations, or even identify the proper OEM partner for your equipment.
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