Pulp & Paper Canada March/April 2015

PULP& PAPER CANADA

OVER 100 YEARS OF SERVING THE INDUSTRY

MARCH/APRIL 2015

HIGHLIGHTS FROM PAPERWEEK CANADA

SAFEST MILLS IN CANADA TOLKO EMBRACES 5S PRINCIPLES

www.pulpandpapercanada.com

New Owners Revitalize Nova Scotia Mills An Official Partner of the Pulp and Paper Technical Association of Canada PPCMarApr2015.indd 1

PAPTAC

Pulp and Paper Technica Association technique de

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PULP& PAPER CANADA

March/April 2015 Vol. 116, No. 2 An Annex Business Media Publication PRINT EDITION ISSN 0316-4004 ON-LINE EDITION ISSN 1923-3515

OVER 100 YEARS OF SERVING THE INDUSTRY

COVER STORY 23 B ack from the Brink of Disaster

Nova Scotia’s pulp and paper sector is smaller but stronger, and more able to compete on the global stage. Analysis by Peter Woodbridge.

FEATURES 11 P aperWeek in Review

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Read highlights of Canada’s largest pulp and paper industry gathering, PaperWeek Canada. Review includes award winners, keynote speakers, biorefinery update, packaging market outlook and technical sessions.

See also – safety presentations from PaperWeek on page 16, mechanical pulping highlights on page 28.

16 S ay Zero Harm and Mean It

A safety slogan is useless if not reinforced by actions.

Managers from the St. Felicien kraft mill and the Vaudreuil Works chemical plant share how they reinforce their safety message every day.

17 W hich are the Safest Mills in Canada?

Results from the 2014 Safest Mill in Canada Contest.

18 P acWest Preview

The PacWest conference moves back to Whistler this year, and has an outstanding line-up of speakers to enlighten participants.

19 T aking Out the Trash at Tolko

At Tolko Manitoba Kraft Paper, when a cleanup inspired by the continuous improvement program filled eight dumpsters with unnecessary paperwork and office waste, the idea spread quickly to other areas of the mill.

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IN EVERY ISSUE 4 Editorial 6 Industry News 10 Opinion: FPInnovations 10 Opinion: FPAC 26 Technology News 29 Classified Ads 30 Bio-Economy MISSION STATEMENT: To promote the pulp and paper industry in Canada by publishing news of its people and their innovations in research, technology, management and financing, as well as forecasts of future trends.

Serving the industry since 1903.

For breaking news, visit www.pulpandpapercanada.com Cover photo: Port Hawkesbury Paper, Port Hawkesbury, N.S.

www.pulpandpapercanada.com

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March/April 2015 PULP & PAPER CANADA

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Editorial

A salute to our thought leaders

L

et me start with congratulations. Congratulations to the winners of Pulp & Paper Canada’s Safest Mill in Canada contest for 2014. Domtar Windsor once again tops the large mills category, but Alberta Pacific and Catalyst Paper Crofton, the two other players in that category, both made significant improvements compared with their 2013 results.

Among mid-sized mills, the Baie-Comeau site of Resolute Forest Products takes first place, followed by Resolute Alma and Resolute Thunder Bay. The company-wide emphasis on safety by Resolute is clearly having a positive effect in reducing the incidence of injury.

In the smaller mills category, Resolute again holds the top spot with zero recordable incidents at the Thorold mill, followed by Sonoco Brantford, which also had zero incidents.

The full list of results is on page 17. If your mill is not participating in this contest, you can still join for 2015. Contact me to discuss rules and reporting.

And more congratulations, this time to PAPTAC and the program committee for PaperWeek Canada. This year’s event offered a lot of valuable information, and Cindy Macdonald had a wide variety of topics. Our coverage of PaperWeek Editor begins on page 11.

I attended a session at PaperWeek Canada in which Eric Ashby of Domtar Windsor spoke about human performance improvement (HPI), an approach he is implementing at the Windsor mill. It is inspiring to hear someone speak of something they are passionate about, but I’m not going to go into much detail about HPI because the reality is that not many mills in Canada are ready to move their safety and workplace culture to that advanced level (Windsor being an exception). Ashby referred to the DuPont Bradley curve, a tool DuPont uses to help clients understand the journey toward world-class safety performance. To implement HPI, companies would have to be beyond what DuPont calls the “supervision level,” where employees are just following rules that someone else makes.

If you are interested in learning more about HPI, Ashby noted that two excellent resources are available free online from the U.S. Department of Energy – the Human Performance Improvement Handbook, volumes 1 and 2. I found them both by searching for “DOE human performance improvement.”

Jean Hamel of FPInnovations organized for PaperWeek Canada what was effectively a large brainstorming session on the topic of industry transformation. Ideas flowed freely and it was fascinating to hear the opinions of people representing all levels of the industry, not just its upper management. One astute comment that I heard went something like this: “I fear that biorefining and bioproducts are taking our superior (Canadian softwood) fibre and crushing it into little bits and losing our quality advantage yet still leaving all our cost disadvantages.”

Ponder these ideas. There’s more to come next month.

Editor CINDY MACDONALD 416-510-6755 cindy@pulpandpapercanada.com Publisher JIM BUSSIERE 416-442-5600 ext. 3606 jim@pulpandpapercanada.com

President & CEO ANNEX PUBLISHING & PRINTING INC. MIKE FREDERICKS mfredericks@annexweb.com Vice President ANNEX BUSINESS MEDIA EAST TIM DIMOPOULOS (416) 510-5100

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Industry News FPInnovations receives $20 million in federal funding The federal government will invest $20.6 million towards reinforcing innovation in the Canadian forest sector through the work of FPInnovations, a research organization focused on the forest products sector.

This funding will support 2015-2016 research by FPInnovations to help develop leading-edge technologies, processes and products in Canada’s forest industry.

Vancouver packaging plants bought by U.S. holding company Crown Paper Group, Inc. has acquired Port Townsend Holdings Company, which includes the Port Townsend Paper mill in Port Townsend, Wash.; the Crown Packaging plant in Vancouver. B.C.; the Boxmaster packaging plant, also in Vancouver;

Briefly…

• Unifor members at Atlantic Packaging have voted overwhelmingly in favour of a new collective agreement that will see increases in wages and benefits, the union states. The new agreement will bring wage increases of 2% in each year of the contract. In addition to a $1,000 signing bonus, workers will receive improvements to their dental, vision and long-term disability programs as well as other monetary items such as allotments for boots, shift premiums and severance payouts, says Unifor.

• The Voith Group is proceeding with a previously announced consolidation of its worldwide administrative functions and capacity adjustment at Voith Paper that will result in a workforce reduction of up to 1,600 jobs worldwide by the end of 2016.

More than half the job losses will be related to Voith Paper. Regarding Voith Paper, at the company’s 2014 annual press conference, Voith reported on the significantly reduced market demand for new machines and major rebuilds in the paper industry and the company’s “very strained business situation” in this segment.

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and distribution centers in Kelowna, B.C., and Calgary.

Crown Paper Group is a holding company created in 2015 for investments in the paper and packaging industries. It was created by the investment firm Lindsay Goldberg, which manages $10 billion of equity capital, and claims to be focused on acquiring well managed businesses and actively helping to build long term value.

“We are energized by the opportunity to work with the customers and employees of the Port Townsend Paper mill, Crown Corrugated, and Boxmaster,” said Crown Paper Group CEO Steve Klinger. “We have a track record of engaging employees in involved and productive workplaces, embracing safe work practices, minimizing our environmental footprint, and partnering with the communities in which we operate.”

Alpac pulp mill will get new Japanese owner Japan’s Hokuetsu Kishu Paper is planning to acquire Canadian pulp producer Alberta-Pacfic Forest Industries Inc. as early as this spring, purchasing all of Alpac’s shares from its current owners, Mitsubishi Corp. and Oji Holdings, according to a story on the web site of Nikkei Asian Review.

This will be the first step into North America for Hokuetsu Kishu Paper, Japan’s fifth largest papermaker. Nikkei Asian Review notes that for Hokuetsu Kishu, domestic demand continues to shrink.

The value of the entire deal is expected to top 6 billion yen ($50 million).

Alpac operates Canada’s newest and North America’s largest, single-line bleached kraft pulp mill. It produces nearly 650,000 air dried tonnes of elemental-chlorine free pulp annually.

Forest industry welcomes trade action against China The trade dispute with China over that country’s imposition of import duties on dissolving pulp moved ahead another step in early February, as the federal government requested a panel at the World Trade Organization (WTO) to resolve the issue.

Last fall, Canada made a request of the WTO for consultations with China.

Since that action was not effective within its 60-day time frame, this request to have WTO adjudicate is the next step.

The Forest Products Association of

Canada (FPAC) and two producers affected by the import duties, Tembec and Fortress Paper, are supportive of the federal government’s trade action against China regarding duties on Canadian dissolving pulp.

Resolute settles legal dispute with Rainforest Alliance over FSC audit Resolute Forest Products has reached a settlement in the legal case launched last May against third-party auditor The Rainforest Alliance. The lawsuit concerned draft audit reports for the Black Spruce Dog River Matawin Forests and Caribou Forest operations in Ontario, related to the Forest Stewardship Council (FSC) certification of these areas.

Under the terms of the agreement, a new corrective action verification audit (CVA) will be conducted for only the Black Spruce Dog River Matawin Forests, located in northwest Ontario. The CVA audit will be completed within six months.

The previous draft CVA audit reports related to Black Spruce and Caribou Forests have been sealed by an Ontario court. Following the upcoming CVA audit, Rainforest Alliance will disclose a public summary of the report findings, per FSC requirements.

New owner will spur growth of Ontario-based packaging supplier PaperNuts Corp., a fledgling Ontariobased developer and marketer of innovative paper-based packaging solutions, has been acquired by Axiom Corp.

Tyler Pearson, CEO of PaperNuts, commented, “We are extremely pleased to have quickly completed this important going-public transaction that should help to accelerate our growth strategy and allow us to better deliver the highest-quality ecofriendly and sustainable paper packaging technologies to businesses of all sizes.”

PaperNuts Corp. owns proprietary technology and intellectual property originally developed in Finland that provides a paperbased alternative to traditional protective packaging options, such as polystyrene foam plastic “peanut” fillers, bubble wrap, air pillows, crumpled paper, foam-in-place, and corn starch peanut products.

PaperNuts are made from 100% recycled paper. The “PaperNuts Converter” machine produces on-demand on-site packaging. www.pulpandpapercanada.com

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Industry News PaperNuts’ new owner, Axiom Corp., is described by the Reuters news service as a development-stage company. The company also has an infrastructure business operating in the eastern African nations of Uganda, South Sudan and Kenya through its wholly owned subsidiary, Acton.

Valmet purchasing process automation business from Metso Only a year after Metso split the company’s pulp and paper business from its process automation operations, the two will be reunited. Valmet Corp. (formerly Metso’s pulp and paper business) has agreed to purchase Metso’s Process Automation Systems business.

The business Valmet is acquiring supplies process automation and information management systems and related applications and services to the pulp, paper, energy and other process industries.

“Through the acquisition of Process Automation Systems, Valmet will become a technology and service company with full automation offering,” says Pasi Laine,

Domtar Windsor manager Eric Ashby named TAPPI Mill Manager of the Year Eric Ashby of Domtar’s Windsor, Que., mill has been selected as PIMA’s Mill Manager of the Year. Ashby was selected for this honor due to his outstanding leadership, management and organizational skills leading to improved results at the Domtar Windsor mill.

“I am honored to receive this award and I do believe it is the reflection of the Windsor team, a great team that I am very proud to be a part of and contribute to,” said Ashby. “This award recognizes all the hard work and accomplishments achieved by our team in Windsor over the years and I’m proud to say they are many.”

PIMA is the management division of TAPPI, the American pulp and paper industry association. The award will be presented during the TAPPI’s PaperCon conference, held April 19-22 in Atlanta, GA. Ashby obtained a Bachelor’s degree in chemical engineering at École Polytechnique, Montreal. He also holds an Executive MBA from Queen’s School of Business and a Master in pulp and paper engineering from McGill University in Montreal.

Ashby began his career as an environmental process engineer at the defunct Repap Miramichi LWC mill in New Brunswick. Throughout his career, he has held positions in six different pulp and paper facilities in four provinces.

Ashby is entering his fourth year as mill manager at the Domtar Windsor mill, an integrated facility producing 650,000 tons per year of uncoated freesheet, where he is responsible for 820 Domtar employees.

PUBLIC AUCTION eAsT ANGUs MASSIVE 2 DAY PAPER MILL EVENT! WedNesdAy, APrIL 15 & ThUrsdAy, APrIL 16 248 rue Warner, east Angus, QC, J0B 1r0 INSPECTION: Monday, April 13 & Tuesday, April 14 from 9:00 to 5:00 & morning of auction days to start of auction.

To arrange an alternate inspection, please contact 416.962.9600.

It is with great pleasure to announce Corporate Assets Inc.’s recent acquisition of the Cascades paper manufacturing facility in East Angus, Quebec. An unprecedented offering of world-class equipment used to manufacture specialty and commodity KRAFT papers will be sold through a Massive 2 dAy PUBLIC AUCTION in April, 2015. The facility has the capacity to produce approximately 100,000 metric tons of paper per year, and has an exceptional reputation for quality due to their extensive capital re-investments into their machinery & equipment.

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Industry News president and CEO of Valmet.

The enterprise value of the acquisition is EUR 340 million. It is expected to be completed by April 1, 2015, subject to approval by the competition authorities.

When Port Hawkesbury Paper reopened under new ownership in 2012, Pulp & Paper Canada reported that the company had been promised a financial package which included: a $24-million loan to improve productivity and efficiency, a $40-million repayable loan for working capital, $1.5 million to train workers, $20 million to buy 51,500 acres of land, and $3.8 million annually, for 10 years, from the forestry restructuring fund to support sustainable harvesting and forest land management.

Maine mill calls Port Hawkesbury Paper “subsidized competition” UPM’s supercalendered paper mill in Madison, Maine, took a temporary shutdown for several weeks earlier this year, citing international competition, energy costs and market conditions, reported the Bangor Daily News.

In a letter advising Maine’s congressional delegation of the shutdown, Russ Drechsel, manager of the mill and president of Madison Paper Industries, is said to complain about “subsidies” given to a competing mill in Port Hawkesbury, N.S. Drechsel told the Bangor newspaper that competition from Port Hawkesbury Paper makes it “difficult for the Madison mill to offer a competitive price as it faces rising power costs during the winter.”

Resolute gets six-month extension for suspended FSC certificate The Forest Stewardship Council Canada has requested a six-month extension to be granted by the certification body Rainforest Alliance for a suspended forest certificate held by Resolute Forests Products in Lac StJean, Que. The deadline for the suspension of this certificate is extended from January 2 to July 2, 2015.

This six-month extension provides the

Government of Quebec with an opportunity to address a land dispute in the area which was a factor in the suspension of Resolute’s FSC certificate.

“FSC is confident in Resolute Forest Products’ ability to reinstate the validity of the FSC certificate in the Saguenay Lac StJean region, while adhering entirely to the FSC standards. The vitality of the forestry sector of this region depends on it,” said François Dufresne, president of FSC Canada.

“We look forward to clear proposals from FSC Canada for resolving the two issues that are responsible for the temporary suspension of the two certificates, while maintaining the viability of our company and the communities in which we operate,” said Richard Garneau, president and CEO of Resolute.

The pulp and paper manufacturer continues to be one of the largest holders of FSC sustainable forest management certificates in Canada and recently successfully renewed its certificates in the Mauricie, Abitibi and North Shore regions of Quebec.

MERGERS & ACQUISITIONS Cascades completes sale of its North American boxboard operations The sale of Cascades Inc.’s North American boxboard manufacturing and converting assets to Graphic Packaging Holding Company, previously announced in December, was completed on Feb. 4, 2015.

Included in the $44.9-million transaction are the Cascades boxboard units in East Angus and Jonquière, Que.; Winnipeg; and Mississauga and Cobourg, Ont. This transaction supports Cascades’ intention to refocus its activities on certain strategic sectors. It does not affect the company’s European-based boxboard operations.

Cascades continues to operate in the materials recovery, packaging and tissue paper sectors.

Atlantic Packaging begins U.S. expansion with joint venture near Chicago Toronto-based Atlantic Packaging Products Ltd. has created a joint venture company that will operate a new sheet feeder business in Carol Stream, Ill., a suburb of Chicago. The new joint venture, BlackHawk Corrugated, will be co-owned and operated by Atlantic and its JV partner StandFast Packaging of Addison, Ill. According to Atlantic Packaging, Chicago is the first of several joint venture initiatives that the company is in the process of developing across the Midwest and Northeastern regions of the U.S. “As a privately held company with a strong balance sheet and a history of successfully green fielding our own paper mills and corrugated plants in Canada, Atlantic is prepared to move quickly and offer new JV opportunities to independent box plants across 8

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several US regions that will create multiple profit centers for our partners and a clear path to full vertical integration that the traditional sheet feeder models simply cannot support,” said Dave Boles, president, Atlantic Packaging. “We are not just looking for sheet supply contracts, but are also seeking to build true partnerships that will thrive and grow with us in the U.S. markets.”

Atlantic’s investment in BlackHawk will exceed $40 million and create more than 100 new jobs in the region. BlackHawk is expected to be fully operational by late 2015.

A company statement says Atlantic’s expansion into several competitive U.S. markets is a critical part of its long-term growth strategy, given the rapid consolidation trends currently occurring in the U.S. and Canadian corrugated packaging markets.

Atlantic Packaging Products is an integrated corrugated packaging company which operates paper and board mills in Canada, as well as a recycling division.

2014

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Canfor’s Taylor pulp mill joins Canfor Pulp subsidiary Canfor Corp. has sold its Taylor, B.C., pulp mill to its subsidiary company, Canfor Pulp Products Inc. This transaction will affect the management reporting structure of Taylor Pulp within Canfor Corp. but is not anticipated to have any operational impacts.

“This transaction serves to align all of our pulp and paper operations under the expertise of our Canfor Pulp leadership team,” said Canfor Corp. president and CEO Don Kayne.

Taylor Pulp employs 106 people and produces 220,000 t/yr of bleached chemi-thermo-mechanical pulp.

PPC www.pulpandpapercanada.com

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TE • • • • •

Kra Sus Pro Pulp UBC

• Pro • TM

PACWEST CONFERENCE JUNE 10 - 13, 2015

“Leveraging our Competitive Advantages ” 2015 EXECUTIVE PROGRAM Committee: Stew Gibson – Catalyst Paper Kelly Parfitt - Canfor Pulp Gord Start - West Fraser-Hinton Pulp Steven Bull - Canfor

Join us again back at: The Fairmont Chateau Whistler

WHISTLER, BC

IBMP ORGANIZING Executive: Eric Bérubé – Buckman North America Scott Curry – CQ Strategy Ajay Vashisht – Quadra Chemicals Tim Jarvis – ERCO Worldwide Drew Lyon - OVAL International

AWARDS * H.R. MacMillan Trophy for BEST MILL PAPER * RUNNER-UP for full length paper (open to consultants and researchers) * BEST SUPPLIER PAPER * BEST NOVICE PAPER for first presentation by author

We are also pleased to present a full Spousal Program

For inclusion in the Program, abstracts must be received by March 31st 2015 with paper completion by MAY 20th Selection of papers is based on several criteria, including originality, technical merit and mill relevance

TECHNICAL SESSIONS • • • • •

Kraft Sustainability, Energy, Environment Process Control Pulp & Papermaking UBC Student Presentations

• Project Management • TMP Technology/Energy Reduction

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WEDNESDAY, JUNE 10 I NDUSTRY MEETINGS: * PAPTAC Councillors (TBC) * Mill Managers & Sr. Executives * Maintenance Managers RT * Energy Reduction * SHORT COURSES: - Project Management - Digester / Brownstock Washing - TMP/BCTMP * Trade Fair

THURSDAY, JUNE 11 To network with peers, industry leaders and technical experts. Enhance professional development learning about new technologies, process improvements and what’s being showcased for the latest industry challenges.

2015 CALL FOR PAPERS

2014 H.R. MacMillan Trophy winner for best Paper presented to OLAF STARCK, Canfor Pulp by Brian Grantham and Stew Gibson

PROGRAM OUTLINE

Time limit for presentations is 20 minutes with 5 minutes for Questions & Answers

* Conference Forum featuring leading Industry Managers & Analysts including: - Brett Robinson, Canfor Pulp - Mike Putzke, Alberta Newsprint - Robert Dufresne - Resolute FP - Balazs Tolnai - Kruger - Catherine Cobden – FPAC - Carol Lapointe - Domtar * Pulp Machine Superintendents RT * Maintenance Managers RT * 2 Technical Sessions * Trade Fair

FRIDAY, JUNE 12 * 5K Fun Run * Trade Fair

* Pulp Machine Superintendents RT * Maintenance Managers RT * 4 Technical Sessions/Panels * Keynote Speaker Feature Luncheon * Awards Dinner David Eaves – The “Open” Revolution

ABSTRACTS

should be submitted to PACWEST 2015 Program Chair: Kelly Parfitt - Canfor Pulp at Kelly.Parfitt@canforpulp.com

www.pacwestcon.net

Feature Luncheon Keynote Speaker

SATURDAY, JUNE 13 * Annual Golf Tournament

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Opinion

Let’s Right-Size the Transportation System

By David Lindsay, president and CEO, Forest Products Association of Canada

F

rom the very beginnings of the pulp and paper industry, transportation has been vital – from the ships delivering square timber to Britain to the trains hauling newsprint to the southern United States. In 1936, Prime Minister Mackenzie King said that “if some countries have too much history, we have too much geography,” and he had it right. Canada’s vast distances underscore the fundamental importance of transportation to our economic history. Our resources of fish, fur and forests led explorers up our waterways and into the heartland of the continent. The building of the Canadian Pacific Railway and the St. Lawrence Seaway were huge visionary projects. These corridors opened up the country and enabled people to get to our resources and our resources to get to markets. Having adequate transportation helped build Canada and adequate transportation is needed now for Canada to reach its economic potential as a trading nation.

However, there’s been little discussion about Canada’s transportation challenges in an era of globalization. Shifting trade patterns make it challenging for transportation capacity to keep pace. With the growing middle class of emerging markets such

as China, Canada’s resources, including forest products, will be in greater demand than ever before. The key question is: do we have the right transportation system today to support this economic opportunity?

Right now the federal government is doing a review of the Canadian Transportation Act. That’s an important step. However Canada needs a much deeper and more comprehensive policy discussion about what is needed to “right-size” the transportation system. It won’t be easy. What is in the best economic interests of one shipper, such as grain producers, might conflict with others, such as the forest industry. The most efficient and profitable way for a carrier to operate might not be optimal for a shipper.

There is also the general public interest of ensuring adequate transportation services for many of remote one-industry towns that characterize Canada’s resource industry. What is required is a joint public-private effort to collect and analyze data, and jointly develop policy solutions.

Let’s be as bold and visionary as our forefathers and develop a robust and efficient 21st century transportation system that would maximize job creation and prosperity for Canada.

FPInnovations and AITF Deliver Joint Pulp and Paper Training Course

By Jennifer Ellson, Senior Communications Specialist, FPInnovations

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s baby boomers start to retire, new engineers fresh out of universities or from other sectors are being hired by Canadian pulp and paper mills. With the labour force renewal that the pulp and paper sector is witnessing, FPInnovations and Alberta Innovates - Technology Futures (AITF) are conducting a joint pulp and paper course to address the industry’s need for training.

The course, which will be held in Edmonton from June 15-19, 2015, aims to improve the skill levels and effectiveness of present and future employees in the industry. It’s an ideal opportunity to learn about the newest developments and latest technologies, as well as to gain perspective on issues facing the sector, especially those encountered by pulp and paper mills in British Columbia and Alberta.

Numerous technical advancements in the pulp and paper industry have occurred in the last decade, and stakeholders need to adapt to frequent changes and technological breakthroughs as the industry moves to new and specialized products. To address the changing needs, the pulp and paper course will cover tissue, packaging and new cellulosic biomaterials.

Participants in this year’s pulp and paper course will benefit from the depth and breadth of knowledge of experts from 10

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FPInnovations and AITF. Through lectures and interactive demonstrations, participants will learn the basic concepts and equipment related to wood chemistry, pulping, papermaking and paper properties, as well as the latest technological developments and trends.

Participants in past pulp and paper courses consider this workshop an effective way to help mills improve their performance through the professional development and training of their employees. Past participants confirm the growing demand for shorter courses with flexible schedules for a busy workforce wanting to upgrade skills, and for newly hired employees wanting to learn the fundamentals of pulping and papermaking.

AITF’s research partnership with FPInnovations stretches back to 1996, when the two organizations signed a joint research consortium agreement for oriented strand board. In 2013, they entered into two collaborative agreements that strengthen their research partnership in the areas of cellulose nanocrystals and engineered composite products.

For more information on the pulp and paper course, contact the course directors: Xuejun Zou at xuejun.zou@fpinnovations.ca, 514-630-4132 Behzad Ahvazi at behzad.ahvazi@albertainnovates.ca.

PPC www.pulpandpapercanada.com

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PaperWeek Canada 2015

PaperWeek Canada:

On the road to transformation The broad-based program of PaperWeek Canada touched on developments in traditional mill operations and market trends, as well as discussions about industry transformation and the bio-economy.

By Cindy Macdonald, editor, and Shaun L. Turriff

I

ndustry transformation through innovation will be a long process, and we’re not there yet. This was the message from the pulp and paper industry leaders assembled for a panel discussion that kicked off the PaperWeek Canada conference and trade show.

PaperWeek Canada took place from Feb. 2 to 5 in Montreal. It is organized by the pulp and paper industry association PAPTAC. David Lindsay, president and CEO of FPAC, described the challenges facing the forest products industry as the business phenomenon of “creative disruption.” He noted that much the planning and mapping work toward transformation is complete, and that we have alignment of the innovation system in Canada. The Biopathways reports developed by FPAC were cited as an example of the planning stage. Now, “we’re changing the business models, and each individual company has to figure out its path.”

“We are on the journey. We’re just not there yet,” said Lindsay.

Paper-based packaging will adapt Holding a printed, corrugated box, Jim Porter told the audience at PaperWeek Canada: “Literally, there is no better product on the planet, as far as I’m concerned, than a fibrebased package.”

Porter is the president, paper solutions, at RockTenn, one of the world’s largest packaging companies. His keynote speech at PaperWeek Canada about trends and opportunities in packaging held optimism for the sector, despite the rapid and complex changes occurring in this market. www.pulpandpapercanada.com

PPCMarApr2015.indd 11

Globally, paperboard grades showed good growth from 2009 to 2014. Boxboard grades grew more than 10%, and containerboard more than 17%. The growth in North America was somewhat less dramatic, but significant nonetheless.

Porter pointed out that his sample corrugated box was designed to display the product on a shelf, printed with full-color graphics as a “print billboard,” and formed with eight corners for lighweighting. He encouraged the audience to “unbound” their thinking, and release the brain power and the science of our industry to address the complex array of factors that are affecting the packaging market.

He discussed how macro trends such as the shift to more diverse demographics (ethnicity and age), increasing use of smart phones, the decline of traditional grocery stores and the growth of small-store formats will all affect package design.

Product differentiation is how fibrebased packaging can help, says Porter. Popup displays and end caps are an opportunity, as is personalization (think of Coke’s recent campaign, for example).

Equipment upgrades meet industry challenges In the more technical sessions related to packaging, Claes Holmqvist of Paperchine discussed upgrades to existing corrugated machines that can be made at relatively low cost. Such upgrades can help packaging producers meet several of the challenges facing that sector, such as decreasing furnish quality, increasing speeds, lighter weights, and optimization over a wide range of grade conditions. Using case studies of machine upgrades, Holmqvist dem-

onstrated lower fibre usage, lower usage of strength additives, lower refining energy usage and increased production rate from lower drying requirements.

Daniel Hédou, AstenJohnson, presented a few case studies where AstenJohnson single seam felts helped mills achieve faster, more reliable dewatering at the nips.

Participants in the industry transformation session shared their ideas on what the industry’s areas of focus should be.

Ultra-fine particle size technology (UFPST) was the subject of a paper by Robert Hardy of Kemira. This technology allows reductions in binder level without a significant decrease in surface strength, which can reduce coating costs. Hardy said UFPST produces a more open coating structure, favorable for digital grade applications, and can reduce the aftercoater drying demand, leading to energy savings. It also provides an environmentally sound alternative to the current binder systems, said Hardy, allowing for a significant reduction in binder levels, lowering the end product’s carbon footprint and concerns around biochemical oxygen demand.

Also in the packaging sessions, Anne-

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15-03-13 2:36 PM

PaperWeek Canada 2015 Christine Eriksson-Patey of GL&V offered a presentation concerning the effectiveness of the company’s hydrocyclones for cleaning OCC pulp. In today’s market, mills may be pushing their systems to extremes.

Small diameter cleaner systems are running at higher than optimal levels, noted the author, and many mills are closing up

their water systems leading to re-contamination. GL&V’s combination light- and heavy-weight cleaning system can lead to a fibre savings of 30%, and improves the removal of stickies resulting in an overall savings for the mill.

David Jones of Buckman introduced a new tool in the toolbox for developing

Bryant Prosser, Marie Dumontier and Dennis McNinch, on their way to the PAPTAC 100th anniversary banquet.

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PPCMarApr2015.indd 12

Glenn Mason, assistant deputy minister, Canadian Forest Service, spoke on the executive panel.

board strength – enzyme strength development products. Jones says enzyme products have been proven in tissue, specialty grades and 100% recycled paperboard grades. He discussed specifically a trial of Buckman’s Maximyze 2566 at Kruger’s Place Turcot recycled mill in Montreal.

Jones explained that enzymes “damage” the fibre on a molecular level, breaking bonds in the cellulose chain, resulting in similar fibre development as refining, i.e. wall stripping, delamination, collapse and fibrillation. This creates more fibre-to-fibre bonding sites.

The goal in the Place Turcot trial was to increase plybond and STFI. The results for white top board were: a reduction in refiner energy, and STFI increased by 8-12%. Plybond was maintained in spec and the machine speed was maintained at normal rates.

For standard linerboard, the results for Maximyze 2566 were: similar refiner energy, maintained machine speed, plybond increased by more than 30%, and there was no impact on STFI. PPC

www.pulpandpapercanada.com

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K

PaperWeek Canada 2015

KRAFT MILLS AT HEART OF

BIOREFINERY K

raft pulp mills are central to the concept of an integrated forest biorefinery, a Swedish forest industry expert told the audience of the International Forest Biorefinery Summit. With add-on processes, many of which are still at the demonstration phase, kraft mills could produce a wide range of bio-based chemicals and fuels.

Organized by Polytechnique de Montreal, the Summit ran in conjunction with PaperWeek Canada 2015 in Montreal on Feb. 2-3.

In his opening keynote presentation, Peter Axegård highlighted the importance of the kraft mill as the heart of the integrated forest biorefinery (IFBR). Axegård is vice-president and director of the biorefining business area of Innventia, a research institute based in Sweden. He noted that kraft mills represent a large amount of infrastructure worldwide, and working with that existing infrastructure makes more sense than greenfield projects. In particular, he stated that kraft pulping must remain the central focus of the biorefinery, with the production of pulp supporting the production of higher-value products Axegård’s keynote speech also reviewed high-value bioproducts under development

By Shaun L. Turriff

by Innventia, including lignin-based carbon fibres and other lignin products, microfibrillar cellulose (for production of clear film) and textile fibres made from cellulose, as well as second generation sugar intermediates (ethanol, lactic acid, acetic acid) and bio-diesel or bio-gasoline from lignin.

One of the more sobering moments in Axegård’s presentation, despite his own declared optimism, came as a reminder of the timelines associated with this sort of product and process development. The LignoBoost lignin extraction process, his example, was conceived in 1996, and commercialized in 2013, some 17 years later.

Just five years ago, when this integrated forest biorefinery conference first began, many industry experts were claiming that much of the biorefining technology being discussed then was still ten to 15 years from commercialization.

A presentation by Adriaan van Heiningen, introduced as the father of the biorefinery concept, catalogued his thoughts on the state of the biorefinery, 10 years after he first defined it. Like Axegård, van Heiningen sees the kraft mill as central to the biorefinery. In his talk, van Heiningen noted the few commercial successes in bio-

refining, and suggested a few reasons why other proposals had failed to take hold in the industry. Successes include Domtar‘s Plymouth mill and Stora Enso’s Sunila mill, using Lignoboost, West Fraser’s Hinton mill in Alberta using Lignoforce, and UPM’s Lappeenranta biorefinery, producing BioVerno, a bio-diesel from tall oil.

For van Heiningen, the future of the kraft pulp IFBR lies in the improvement of the pulping process, with gains in either production and/or quality, to cover the cost of feedstock and energy increases for new product streams. Overall, van Heiningen considers the IFBR as a modest success, and foresees growth of the concept in the future, especially as greenhouse gas emissions continue to be a worldwide concern and continue to function as a policy driver.

Policy and public support Evelyn Thiffault, Laval University, discussed issues surrounding policy and greenhouse gas emissions in her talk on biomass supply chains and bioenergy.

Thiffault says that the mobilization of more biomass needs better integration, where even the harvester knows what is being harvested for which purpose and where to send it. Further, conversion technology needs to be improved to deal with feedstock variation. Liquid fuels such as biodiesel and bioethanol, for Thiffault, offer the lowest substitution cost, and for now are a solid option.

These themes of integration in harvesting, public support and replacement cost all had echoes in other presentations during the Summit.

Jean-Philippe Jacques, InnoFibre, sug-

Kraft pulp mill process outline, courtesy of Valmet. www.pulpandpapercanada.com

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PaperWeek Canada 2015

PAPTAC Awards 2015

John S. Bates Memorial Gold Medal Pierre Lapointe, president and CEO of FPInnovations, received one of PAPTAC’s highest individual honours in recognition of his contribution to the science and technology of the pulp and paper industry.

Safety Leadership Award Sonoco Brantford Jim Maloney accepted the award.

Mill Manager of the Year Award Mike Putzke, Alberta Newsprint Co. Shown are Ron Stern, Pacific West Commercial, part owner of Alberta Newsprint, and Mike Putzke Pulp and Paper Industry Builders Award Bernard, Laurent and Alain Lemaire, founders of Cascades Inc., for their visionary entrepreneurial spirit

PAPTAC Fellows

John S. Bates Memorial Gold Medal

Honorary Life Memberships were conferred to the following individuals for their extraordinary dedication to the association: Patrice Mangin, professor, UQTR and former chairman of PAPTAC Robert Wood, former executive director David H. Paterson, former manager of the CPPA Technical Section The title of PAPTAC Fellow was conferred to all past Chairs of the association and Gold Medal Winners. The following individuals are also conferred the title of PAPTAC Fellow: Yonghao Ni, professor, UNB Paul Stuart, professor, Polytechnique de Montreal Mike Bradley, Canfor

Howard Rapson Memorial Award

Member Leadership Award

Member Leadership Award Suzanne Hohmann, Irving Paper, for her outstanding leadership as Chair of the PAPTAC Atlantic Branch Jean Paris, Polytechnique de Montréal, for his long-term involvement in PAPTAC’s Research Community and the International Forest Biorefinery Summit Howard Rapson Memorial Award for Best Chemical Pulp Bleaching Paper Sandra Beder-Miller, BTG Americas Inc., for her paper entitled “Is conductivity the best measurement of bleach plant carryover?”

Pulp and Paper Industry Builders Award

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Mill Manager of the Year Award

Douglas Atack Award for Best Mechanical Pulping Paper André Pelletier and Kecheng Li, UNB; Martin Fairbank, Resolute Forest Products; Mark Frith, Port Hawkesbury Paper; and George Court, Irving Paper; for their paper entitled “Enzymatic pre-treatment of wood chips for energy savings in TMP refining.”

www.pulpandpapercanada.com

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PaperWeek Canada 2015 gested that significant cost could be saved in biomass treatment and transport with regional biomass conditioning platforms, a combination of mobile grinder and screen, which has the benefit of mobility, control of particle size, removal of contaminants and fines, and a reduction of conditioning and transportation cost. This sort of technology, integrated into current practice, or the mobile pyrolysis units suggested last year by Jean Paris of Polytechnique de Montreal, could result in the sort of novel harvesting techniques needed to improve both biomass mobilization and the use of dead trees in the industry.

From R&D to reality Closing the Summit, a panel of industry experts, from pulp and paper companies, end users, governments and associations, discussed means of producing, and then selling, high-value products from an IFBR. Highlights of the panel included Tom Browne, FPInnovations, suggesting that the primary focus of the biorefinery must be chemicals, marketed directly to the end

user, with energy or fuel as a secondary product of those processes. While acknowledging the importance of drop-in biofuels based on the immensity of existing infrastructure, he suggested that bio-fuel would always suffer against fossil fuel in value.

Martin Fairbanks, Resolute Forest Products, highlighted the industry’s depth of knowledge in forestry and forest products while lamenting the public’s misunderstanding of the industry’s green credentials. Common issues raised included the need for consistency in the end product to compete with current products (largely from oil), the need for a clear, consistent, long term policy environment to mitigate investor risk, and the overall lack of mature technologies.

Depolymerization overcomes challenges of lignin The summit’s second keynote was delivered by Charles Xu, Western University.

Xu spoke of efforts to overcome by depolymerization some of the challenges inherent to working with lignin. According to Xu, kraft lignin, as is, can replace up to 30% by

weight of the components in phenol formaldehyde (PF) resins and polyurethane (PU) foam. With de-polymerization, however, the potential replacement percentage in these applications climbs to between 50 and 100%, he said.

Depolymerization of the lignin into specific bio-phenols, bio-polyols and bioaromatics, with a subsequent re-polymerization, allows for synthesis of several biobased materials, including phenolic resins and foam, rigid polyurethane foam, epoxy resins, UV curable/absorbing resins, asphalt modifier, and carbon fibre. Depolymerization overcomes the challenges presented by lignin, namely its high molecular weight, low reactivity and low strength.

So far, only a few kraft mills globally have implemented commercial-scale biorefinery processes. Domtar’s Plymouth, N.C., mill began selling lignin in 2013, and West Fraser is currently installing lignin separation equipment at its Hinton, Alta., pulp mill. Other by-products of the kraft pulping process are in the pilot or demonstration phases.

PPC

We don’t just talk about innovation.

We innovate.

See how FPInnovations takes part in the

technological advances of the pulp,

paper and bioproducts sector. fpinnovations.ca Follow us

www.pulpandpapercanada.com

PPCMarApr2015.indd 15

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Safest Mill

Say

ZERO HARM

A safety slogan is useless if not reinforced by actions. Managers from the St. Felicien kraft mill and the Vaudreuil Works chemical plant share how they reinforce their message every day.

and mean it

By Cindy Macdonald, editor

S

peaking at PaperWeek Canada, Steve Pelletier and JeanFrançois Nadeau shared their stories of making a safety culture a reality in an industrial environment. Pelletier, from Resolute Forest Products’ St. Felicien kraft pulp mill, embraces the mantra “No injury, no pain.” Nadeau is plant manager for Rio Tinto Alcan’s Vaudreuil Works, a chemical plant where the rule is “zero harm.”

The St. Felicien mill has gone through several management and ownership changes in the past decade, and through that time has implemented a gradual culture change. The mill was purchased by Resolute in 2012, and has markedly improved its safety record since then.

To effect culture change, you need to talk about the objective often, said Pelletier. St. Felicien has daily “tailgate” meetings, which always include a safety discussion. Other factors in St. Felicien’s improvement have been: involvement by top management, benchmarking within the corporation, and sharing of Resolute’s safety alert and incident reports.

“In 2012, we became aware we had to change something, and

that we had to focus on behaviour,” Pelletier recalled.

Frontline supervisors are receiving training in leadership, courage, rigor and will. Although the company emphasizes rigor and awareness, it sometimes has to apply discipline as well, said Pelletier. One employee was fired recently over a locking procedure failure. Pelletier concedes that union officials were very concerned about disciplinary action, but one-on-one, he said, the workers see that the safety procedures are in place for their benefit.

Pelletier noted that the site had hundreds of first aid incidents per year during the 2004-2008 period. Then came a significant drop to the 100-150 level. Once the mill began to implement its culture change in 2012, another significant improvement occurred.

In 2013, 39 first aids were recorded, 44% fewer than in 2012. The next year first aids dropped to 17, another drop of 44%.

The mill had one recordable incident in 2013, and two in 2014, giving it a recordable incident rate of less than 1 each year.

Now that the mill has made progress in its safety goals, injuries and first aid incidents are no longer the best indicators, Pelletier said. The safety team will now focus on monitoring

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Safest Mill near misses and dangers.

St. Felicien has implemented a hand safety program, equipping employees with retractable safety knives and cut-resistant gloves, as have most Resolute mills. Chemical safety is another area in which St. Felicien has learned from its Resolute peers. The company insists on full personal protective equipment when handling chemicals – suit, face shield, etc. St. Felicien has experienced no chemical burns since this policy was implemented. Also, flange covers have been installed on every flange that carries chemicals.

Chemical burns are a major safety concern at Rio Tinto Alcan’s Vaudreuil Works as well. More than 500 employees work at the site in Jonquière, Que. Vaudreuil Works is the only alumina refinery in Canada. It also provides auxiliary services such as compressed air and steam to the Jonquière complex, and maintains a fluoride plant (the only one in North America).

Jean-François Nadeau used to work in the pulp and paper sector, but is now plant manager for Rio Tinto’s Vaudreuil Works.

“If one of the tools I present today help you to prevent one injury, then I have achieved my goal,” he told the PaperWeek audience.

In 2014, Vaudreuil Works had only two recordable incidents, for an OSHA rate of 0.27.

What if a catastrophe occured?

Rio Tinto’s safety strategy has three areas of focus: injury reduction, elimination of fatalities, and catastrophic event prevention.

During shutdowns, Nadeau says Vaudreuil Works can have more than 1000 people working on the site. One tool that is used with regard to contractors is a grid which evaluates the skills and experience of the contractor and the risks of the particular job. Risk and experience are ranked as red, yellow or green. A contractor will not be assigned a job with a risk level that exceeds his company’s experience rating.

Among Nadeau’s fatality elimination tools is a method of handling SPIs (significant potential incidents). If an SPI is identified, the safety team has three months to submit a plan to mitigate the risk. Vaudreuil Works has a fatality prevention committee, which is tasked to challenge recommendations and make sure corrective actions are applied.

For catastrophic event prevention, Vaudreuil Works employs a “critical control monitoring plan.” Identify what is “critical” at your plant, Nadeau suggested, and then audit every week the emergency procedures for each critical process or piece of equipment.

Nadeau also suggested semi-quantitative risk assessments. These assessments identify what type of catastrophic events could happen to your plant, and identify how to resolve each event.

Both presenters agree that it is daily repetition of the safety message and enforcement of procedures that will ensure zero harm.

PPC www.pulpandpapercanada.com

PPCMarApr2015.indd 17

Safest Mill in Canada, Total Total 2014 Results recordable hours incidents

worked Frequency

CATEGORY A – Over 80,000 manhours per month Domtar Inc., Windsor, QC Alberta Pacific Forest Industries Inc., Boyle, AB Catalyst Paper, Crofton, BC

3 5 14

1,514,205 1,036,240 1,229,006

0.40 0.97 2.28

0 1 2 2 4 6 5 7 7 11 9 8 9 14 11 20

671,364 717,334 639,853 626,267 601,337 800,643 651,531 661,423 633,135 868,482 709,254 630,234 674,309 867,151 613,991 613,597

0.00 0.28 0.63 0.64 1.33 1.50 1.53 2.12 2.21 2.53 2.54 2.54 2.67 3.23 3.58 6.52

0 0 1 1 1 1 2 1 2 2 2 2 2 5 4 3 3 4 7 10 10 11 7 17 4 11

245,911 136,129 410,039 362,719 321,552 289,685 458,511 218,310 429,834 335,692 292,227 272,188 236,785 529,760 411,982 263,129 235,219 300,113 487,247 567,620 520,114 568,196 287,134 583,821 108,541 291,289

0.00 0.00 0.49 0.55 0.62 0.69 0.87 0.92 0.93 1.19 1.37 1.47 1.69 1.89 1.94 2.28 2.55 2.67 2.87 3.52 3.85 3.87 4.88 5.82 7.37 7.55

CATEGORY B – 50,000 to 80,000 manhours per month Resolute Forest Products, Baie-Comeau, QC Resolute Forest Products, Thunder Bay, ON Resolute Forest Products, Alma, QC Weyerhaeuser Canada, Grande Prairie, AB Tembec – Kapuskasing Operations, Kapuskasing ON. Irving Pulp & Paper Ltd., Saint John, NB Irving Paper, Saint-John, NB Canfor, Prince George Pulp & Paper, Prince George, BC Hinton Pulp (Div. Of West Fraser Mills), Hinton, AB Catalyst Paper, Powell River, BC Zellstoff Celgar Limited, Castlegar, BC Twin Rivers Paper Co., Edmundston, NB Northern Pulp Nova Scotia Corp., New Glasgow, NS Canfor, Northwood Pulp Mill, Prince George, BC Catalyst Paper, Port Alberni, BC Kruger Inc., Bromptonville, QC

CATEGORY C – Less than 50,000 manhours per month Resolute Forest Products, Thorold, ON Sonoco Canada Corporation, Brantford, ON Resolute Forest Products, Clermont, QC Resolute Forest Products, Iroquois Falls, ON Resolute Forest Products, Amos, QC Strathcona Paper LP, Napanee, ON Resolute Forest Products, St-Felicien, QC Resolute Forest Products, Gatineau, Que. Resolute Forest Products, Laurentide, QC Resolute Forest Products, Kenogami, QC Quesnel River Pulp, Quesnel, BC Millar Western Forest Products, Whitecourt Pulp, Whitecourt, AB JD Irving Ltd., Irving Tissue, Saint John, NB Canfor, Intercontinental Pulp, Prince George, BC Meadow Lake Mechanical Pulp Inc., Meadow Lake, SK Tembec Inc., Matane, QC Slave Lake Pulp Corporation, Slave Lake, AB JD Irving Ltd., Lake Utopia Paper Ltd., St. George, NB Alberta Newsprint Company, Whitecourt, AB Daishowa Marubeni International, Peace River, AB Kruger Inc., Trois-Rivieres, QC Cariboo Pulp and Paper Co., Quesnel, BC Resolute Forest Products, Dolbeau, QC Kruger Wayagamack Inc., Trois-Rivières, QC Norampac Inc., Kingsey Falls, Que. Kruger Inc., Montreal, QC

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PacWest Explores Our

Competitive Advantages

By Cindy Macdonald, editor

Photo: Mike Crane/Tourism Whistler

Preview Management

Driving to Whistler for PacWest? This will be your view.

W

estern Canada’s annual gathering of the pulp and paper industry is returning to Whistler this year, on June 10-13. As has been the case in recent years, the 2015 edition of the PacWest conference is characterized by a strong technical program.

The main conference forum on Thursday morning, picking up on the event’s theme, “Leveraging our Competitive Advantages”, will feature a number of experienced and knowledgeable industry executives. Scheduled to speak are: • Brett Robinson, CEO, Canfor Pulp • Mike Putzke, general manager, Alberta Newsprint • Robert Dufresne, vice-president, Resolute Forest Products • Balazs Tolnai, general manager, technology, Kruger Inc. • Catherine Cobden, executive vicepresident, Forest Products Association of Canada • Carol Lapointe, mill manager, Domtar Kamloops

18

Thursday afternoon and Friday are set aside for technical sessions and a trade fair. The technical sessions will cover kraft pulping, sustainability, energy, environment, process control, pulp and paper making, project management and TMP technology. Also on the schedule this year are presentations by UBC students, following up on their successful session at last year’s conference.

PacWest will also host roundtable discussions for mill managers and pulp machine superintendants. The roundtables are by invitation only; see www. pacwestcon.net for more details on participating.

The keynote speaker at Friday’s feature luncheon is David Eaves, an activist for open government and open data. He writes and speaks on the subjects of open innovation, public policy, public service sector renewal, open source and network systems.

Rounding out the schedule are several social events. Friday morning PacWest

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PPCMarApr2015.indd 18

attendees are invited to join the 5K Fun Run. Later that evening is a cocktail reception and the awards dinner. Saturday, PacWest wraps up with a golf tournament.

Please visit the PacWest web site to preregister for golf.

There is a spousal program planned during PacWest, and there are plenty of activities to do in Whistler Village. According to the Whistler.com web site, available in June are canoe, kayak and whitewater rafting excursions, zipline and bungee adventures, hiking and horseback riding.

Also, the new Peak 2 Peak Gondola ride provides incomparable views. Spanning 4.4 km, the new gondola is an engineering marvel that connects Whistler and Blackcomb Mountains. For those who are technically inclined, check out the Peak 2 Peak viewing platform to get an up close look at the inner workings of the lift.

PacWest is organized by the Pacific and Western branches of PAPTAC and IBMP, a group of suppliers to the pulp and paper industry.

www.pulpandpapercanada.com

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Management

Photo: Mike Crane/Tourism Whistler

Continuous Improvement Takes Hold at Tolko

Successful continuous improvement programs have an impact on the overall culture within a company. At Tolko Manitoba, a cleanup inspired by 5S +1 principles filled eight dumpsters with unnecessary paperwork and clutter, and the idea spread quickly to other areas of the mill.

By Joe Weltner, RLG International

C

ontinuous improvement (CI) programs using Lean Six Sigma have been implemented in both small and large organizations over the past 60 years. Lean Six Sigma methodologies were first pioneered by Henry Ford. Later W. Edwards Deming brought them to Japan where they were adopted by Toyota.

Lean programs focus on eliminating waste in the organization in many ways.

Lean is defined as reducing waste and streamlining a process, while waste is defined as an unnecessary activity.

Successful CI programs have an impact on the overall culture within the company.

That has been the case at Tolko Manitoba Kraft Paper, The Pas, Manitoba.

“Continuous improvement is involved in all aspects of our business operations,” explains Andre Murphy, maintenance and engineering manager, Tolko Manitoba. “It starts with our safety culture, as safety is first in all we do. It is embedded in the work we do to always be looking for the best approach to our daily work, to be considering the quality of the work and to ensure we are always taking care of the environment in which we operate.”

A previous article in Pulp & Paper Canada recounted the efforts of employees at Tolko’s The Pas mill to use continuous improvement within their safety culture.

The improvements have been sustained for several years and have reduced the mill’s

This is the office team in the midst of their 5S event, filling dumpsters.

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PPCMarApr2015.indd 19

lost time accidents (LTA) by 75%. The pulp and paper operation reduced LTAs from 12 in 2012, to four in 2013 and only one in 2014.

Tolko Manitoa has also conducted training on continuous improvement team problem-solving and has woven these CI techniques with previous learning and programs on root cause analysis and defect elimination.

Continuous improvement should be measured If an organization decides to implement a continuous improvement effort, it must be able to articulate the purpose and results it is hoping to gain from the effort and cost involved. There has to be a compelling reason and focus for engaging the workforce.

The focus could be to enhance customer service, to reduce manufacturing costs, or to improve the quality of products and services. Many organizations have found that a CI program gave them a real competitive advantage in their market place.

Some examples of CI team improvement efforts resulting in measureable savings or process improvements are: • Reduced the amount of time to conduct safety indoctrinations (cost of labor); • Reduced the amount of time to burn hog in a steam and recovery power boiler (cost of fuel); • Improved the efficiency and cleanliness of the offices and shop areas (safety hazards).

There is value in bringing all the parties together to resolve problems and improve

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Management

What is 5S?

processes. It is important that improvements are quantified as much as possible to show the gains and improvements.

For the safety indoctrination benefit mentioned above, one paper mill reduced the time needed to complete contractor indoctrination from 2 hours to 45 minutes.

The company estimates the savings from this to be $50,000 for a typical shutdown.

Instilling performance management to properly value, track and report the financial benefit of the CI projects is advisable.

The value of CI programs is based on the delivery of the results and process improvements. It is also important to ensure that controls are in place to sustain the results.

SUSTAIN Sitsuke

20

Keeping work places clean, efficient and organized reduces waste and improves productivity

STRAIGHTEN Seiton

Arrange and label items so they are easily located

STANDARDIZE Seiketsu

2

SHINE Seisou

H I

Clean and inspect – ensure that everything and all work areas are clean and clear

the areas being organized, which helps with sustainability and standardization.

“I have to admit, I was very skeptical when we first introduced 5S at an office meeting. We scheduled and conducted the 5S sorting event, where we had our plant manager kick it off and contribute, and we provided lunch,” recalls Marlow.

“We divided the offices into three teams, each assigned a different area to work on.

I was amazed at the excitement and effort that was put into this sorting event. Eight dumpsters later, we had an amazing overall impact on the appearance and efficiency in our offices. What’s great is that we have continued to maintain and improve on the 5S in the offices daily.”

5S can be used as a foundation to any CI effort. There are dozens of resources and on-line tools to assist in rolling out a successful 5S program.

The purpose of 5S is to eliminate waste, support the operator, prevent problems, standardize the process, and enable continuous improvement. The benefits of the program include process consistency, greater process ownership, higher equipment availability, lower costs and a safer and better working environment. 5S is the foundation for lean activities and continuous improvement within most successful CI programs.

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Remove everything from the workplace that is not needed for production

Create standards so abnormalities are easy to recognize; checklists and audits are very helpful

5S +1 inspires change at Tolko paper mill 5S +1 was developed in Japan and was identified as one of the techniques that enabled just-in-time manufacturing. 5S provided a structure for continuous improvement programs with a series of identifiable steps, each building on its predecessor for workplace organization. The “+1” refers to adding safety to traditional 5S programs.

Jackie Marlow, site controller at Tolko Manitoba, recently helped spearhead an effort in the administration offices of the mill that resulted in improvements to the overall organization of the offices; reduced clutter, outdated and obsolete documents; streamlined offices; cleaned out conference rooms and storage areas; and even had an impact on the way employees organize their computer desktops. The office team cleaned out and removed eight dumpsters of outdated and unneeded items in period of two days.

This 5S effort was piloted in the heavy equipment garage, then spread through the mill to the offices, engineering department and finally to the woodlands offices. Each of these areas followed the steps of 5S and started with sorting or removing unneeded and outdated items. The best way to do this is to conduct a 5S event and set a time to kick it off with support from senior management and other departments that have gone through the process. It is recommended that you allocate a set period of time (2-4 hours) and kick it off or end with a lunch/ BBQ to add some team building and fun to the event. These events can really build a sense of ownership among employees of

SORT Seiri

Put a schedule and system in place to sustain the workplace in 5S condition

Continuous improvement teams & problem solving model Toyota created the seven step problemsolving approach, sometimes referred to as the A3 approach (referring to a size of paper). Boeing, British Petroleum (BP), Chevron, Toshiba, Motorola and many other top 100 companies utilize a very similar problem-solving model in their CI efforts.

The seven step problem-solving model brings the continuous improvement (CI) process to the front lines, presenting an opportunity for gaining total engagement of all employees within the organization.

The Boeing Chinook helicopter plant in Philadelphia, PA, for example, had a union agreement specifying that every employee would be involved on a CI team and was allocated one hour a week to work on a team focused on continuous improvement efforts.

CI programs create an environment in which the engagement of the front line employees evolves to a proactive problemsolving culture. The CI program encourages teams to identify problems, to utilize the model to identify root causes and to recommend possible solutions which can be presented to senior management for approval and implementation. Once the culture sees the management team is supwww.pulpandpapercanada.com

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portive and approves some of the recommendations, more problems surface and other suggestions are implemented which creates a culture of engagement based on making “continuous improvements” in the workplace.

“In our paper mill we have seen significant results through the use of CI teams.

We formed a team in our steam and recovery plant to reduce the time it takes to burn down our ash bed in the power boiler. We came up with some suggestions and changes to our procedures which resulted in a savings of more than $100,000,” says Blair Rydberg, site manager, Tolko Manitoba.

Similary, Butch Yellott, senior director for Alcon Industries, says his company has used lean systems in the plant for the past 24 years and has increased output by 373% within the facility. “We implemented CI teams and 5S through out our manufacturing facility and continue to monitor and sustain our CI culture through Visual

Andre Murphy, engineering and maintenance manager with Tolko Manitoba, says continuous improvement is now involved in all aspects of the mill’s business operations.

Management and Standard work.”

Back at Tolko Manitoba, the 5S and continuous improvement culture has taken hold. “It is great to see people taking more pride in their work areas,” says Rydberg. “We have an aging building and work areas (over 50 years old), yet we saw people taking the time to straighten confer-

ence room chairs after meetings, to clean the white boards and to remove all trash.

They cleaned up after themselves versus expecting someone else to do it.”

PPC Joe Weltner is a project manager with RLG International.

Table 1. Seven step problem solving

STEP

DELIVERABLE

POTENTIAL TOOLS

Define the problem

a. Define customer needs, wants b. Scope the activity c. Write a problem statement d. Team membership agreed e. Stakeholder analysis

Problem statement Process map Stakeholder analysis

Go see and assess the problem

a. Quantify needs with metric b. Collect and check data c. Finalize metrics d. Establish the current state e. Establish future state/improvement goal and timeframe

Process map value stream Waste and time analysis Improvement goal and timeframe Data collection 5s, swim lane process map

Identify root causes

a. M ake a list of potential root causes b. P rioritize potential root causes

5 Whys Fishbone diagram Multi-voting Prioritization criteria matrix

Propose solutions

a. G enerate solutions, existing or new b. Prioritize solutions

Brainstorming Filtering matrix Variance reduction Risk assessment

Build and execute the plan

a. Pilot/test solutions b. Implement plan

Action planning Gantt chart

Validate and sustain results

a. Validate the change a. M ake a list of potential root causes

Dashboards SOPs

What did we learn and what’s next?

a. Transfer/sustain b. Update database

Closeout checklist

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Analysis

Back from the Brink of

DISASTER T

hree years ago, Nova Scotians were stunned by the closure of two of the province’s long established pulp and paper mills – the New Page paper mill at Port Hawkesbury and Resolute Forest Products’ Bowater Mersey newsprint mill at Liverpool.

Another casualty was soon to follow. The Minas Basin recycled paperboard mill, which had operated since 1927, closed its doors permanently in November 2012.

The three mill closures resulted in the loss of 1,455 direct jobs along with numerous indirect and spin-off jobs. Negative impacts were proportionally even greater in certain communities. Small woodlot timber suppliers lost their markets, and some lost their livelihood. Sawmills lost their local markets for wood chips. Several lumber mills and other wood product plants closed forever.

Many out-of-work forestry and mill employees went straight to the airport, and flew to Alberta’s oil patch for work. Others found jobs in other sectors in Nova Scotia. Many simply gave up on forestry as a future.

The province’s treasury also suffered. Export earnings by the sector fell by more than 50% in 2012 (Figure 1). The outlook looked extremely bleak. Without a viable pulp and paper sector to buy sawmill residual woodchips, hog fuel and private woodlot timber, the province’s forestry sector was on the verge of an almost total meltdown. A complete collapse was imminent.

Nova Scotia’s pulp and paper sector is smaller but stronger, and more able to compete on the global stage.

By Peter Woodbridge

New capital, new ideas Today, the story is very different. Nova Scotia’s pulp and paper sector has pulled back from the brink of the 2012 mill closures disaster. The industry is smaller, of course. Now the pulp and paper sector comprises just two mills – Northern Pulp at Abercrombie and Port Hawkesbury Paper (formerly owned by New Page).

The two firms have different owners than those who controlled the sector prior to 2011. The new owners are investing substantial new capital to rebuild these mills into state-of-the-art, globally competitive and long-term sustainable enterprises.

Not just new capital investment is involved.

Ron Stern’s group of investors and senior managers are repositioning Port Hawkesbury as a long-term global competitor in value-added publication and printing papers. Jackson Wijaya, the young Chinese entrepreneur who owns Northern Pulp through Paper Excellence, has introduced an innovative new business model into Canada – one that is focused on manufacturing tailormade long-fibre pulps to meet the needs of Asia’s rapidly growing paper and tissue industries.

Both businessmen have brought fresh new ideas, new attitudes and innovation. As a result, Nova Scotia’s pulp and paper sector – which almost disappeared three years ago – is now emerging as a more profitable and sustainable long term contributor to the province’s economy. Many existing jobs were saved, and new ones created.

Although it is smaller, the pulp and paper sector has recaptured 85% of the export sales revenues it lost in 2012. Today’s jobs are more secure. The sector continues to improve its environmental performance. With help from Canada’s declining dollar, export earnings are set for growth.

Figure 1. Nova Scotia’s pulp and paper sector turns the corner. www.pulpandpapercanada.com

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Analysis Accolades to the Nova Scotia government It is unfashionable to congratulate politicians and government ministry employees on a job well done. But that is exactly what the people of Nova Scotia should be doing today. It was a few brave political leaders, as well as deputies and staff from a handful of ministries, who stuck out their necks and took action to help save the industry.

It was a tough battle. There were times when mill rescue efforts could have fallen apart. But finally they worked.

There were some important back-stories that heightened the drama. At the time, there was legislation on the books to reduce the level of clear-cutting by 50% over five years. This would have

Figure 2. Nova Scotia’s pulp and paper sector recovery

increased the industry’s wood costs substantially. The province purchased, and subsequently re-allocated, the Resolute Forest Products lands and other assets. There were regulations to limit other aspects of Crown timber harvesting, and to re-assign Crown lands to protected areas and parks – taking them out of the province’s “working forest.”

Northern Pulp exploiting a niche The kraft pulp industry (in which Northern Pulp is now a global player) has become re-focused on the world’s fastest growth market for imported pulps – China. Tough competition exists. In the southern hemisphere, new state-of-the-art pulp mills produce large volumes of low-cost, high-quality hardwood pulps. Based on fast-growing, highly productive plantation species, they are set to capture the lion’s share of global pulp demand.

How can Northern Pulp compete with these low-cost pulps that are now setting the baseline for future global pulp prices?

The mill’s response is that, as a producer of softwood long-fibre kraft pulps, it can fill a niche market need in fast growth export markets. Long-fibre pulps are essential for some paper products – and make up 10%-15% of papermakers’ imported pulp requirements. The innovative Northern Pulp business model, based on high utilization of manufacturing capacity, substantial upgrading of capital equipment and high maintenance levels throughout the mill (which were neglected by previous owners) is already achieving significant success.

Northern Pulp has been a steady and, in recent years under its new ownership, growing success story for Nova Scotia. Although there is some domestic demand for market pulps, the upgraded mill is now able to compete strongly in international markets.

Figure 2 shows that Nova Scotia’s export earnings from its high quality and tailor-made pulp exports hit a recent record – rising to $238 million in 2014.

An uphill battle for paper

Figure 3. Canadian exports: long-term decline in paper, steady demand for long-fibre pulp

Figure 4. Nova Scotia softwood lumber exports moving higher

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In many respects, Port Hawkesbury Paper – producing grades of paper for which global consumption growth is slow – faces an even tougher uphill battle against global competitors. Yet the company is making good headway.

Closures of papermaking capacity in Canada, the U.S. and Europe are helping the paper mill. But significant additional mill capacity outside Nova Scotia needs to be closed before market equilibrium will be achieved. Management has not waited around for this to happen. Instead, large investments are being made in people and in targeted marketing of the mill’s high quality papers.

To understand the magnitude of Canada’s lost capacity in papermaking – and why Nova Scotia’s recently improved competitive position needs to be nurtured carefully – it is insightful to look at the data in Figure 3.

Over the past decade or more, dozens of paper mills in Canada and elsewhere, producing newsprint, publication papers, printing papers and paperboards, have been closed permanently because they were no longer financially viable. In part, this situation is driven by consumer demand (e.g. declining demand for newsprint in developed countries). Demand for these grades has shifted in part to new fast growth markets, such as Asia.

In other cases, some Canadian mills have been closed primarily www.pulpandpapercanada.com

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Analysis because their supplies of economically accessible standing timber and residual fibre have been compromised or withdrawn. As a result, Canada now has lost much of its former dominant position as a major supplier of paper to the world.

From an export earnings perspective, Canada’s loss of global competitiveness in papermaking was a decline of nearly $8 billion in annual revenues over the period from 2002 to 2014. Few other manufacturing industries in Canada have experienced such a fast pace of decline over such a short time.

For the forest dependent communities involved, the impacts have been devastating. In the case of the rural communities which have survived – including those in Nova Scotia – it is imperative that complacency should not cloud peoples’ thinking about the future of the surviving mills. There is no free ride.

Competition is not just global, but also regional, especially in the search for economically accessible wood fibre. Nova Scotia’s pulp and paper mills compete regionally for fibre supply from sawmills and other wood products plants. Fibre procurement always is a challenge for the province’s pulp and paper sector.

Wood products and bio-energy Fortunately, Nova Scotia’s wood products industry and its bio-fuel sector are integrated closely with pulp and paper manufacturing.

To make a profit, sawmills sell whitewood residual by-product chips and sawdust to the pulp and paper mills. Huge volumes of residual wood chips are involved. It is essential income for sawmills.

Today, there is a strong recovery underway in Nova Scotia’s softwood lumber sector. Export growth is aided by the recovering U.S. market and buoyant demand for pulp-making chips.

Increasingly, this recovery has focused its attention on the needs of domestic markets in the Atlantic Provinces and parts of Quebec.

Exports sales, which plummeted from $250 million in 2005 to only $67 million by 2009, are recovering well (Figure 4).

The path ahead As with all manufacturing sectors, many challenges lie ahead for Nova Scotia’s forest industry. The industry today is not the industry that it was just a few short years ago. It is much leaner, more productive, and more globally competitive – with an increasingly optimistic outlook and future.

Currency fluctuations are a double-edged sword. Today’s CAD-USD rate favours Canada vs. U.S. producers. But now there are rumblings of protectionism from parts of the United States.

European producers of forest products, pushed out of traditional fast growth markets by turbulence in the Middle East and North Africa (MENA market), are enjoying a substantial boost to export competitiveness from the low-valued Euro. With low ocean rates, they are starting to ship to the U.S. – and the U.S is buying.

The China market for pulp has slowed recently, but medium- to long-term consumption growth throughout Asia is encouraging.

Nova Scotia’s lumber sector is anticipating, within a few years, a “super cycle” of high demand and higher prices. Still left out in the dark, however, are Nova Scotia’s private wood lot owners, who account for more than 60% of the ownership of the province’s forests.

Comparatively few private woodlot owners are involved in www.pulpandpapercanada.com

PPCMarApr2015.indd 25

commercial transactions with the forest industry. Some do not wish to participate for a variety of reasons, including a preference for un-harvested forests and lifestyle. Many others have indicated that they really do want to participate in commercial markets, but at the right price point and under the right conditions.

For the next decade and beyond, Nova Scotians will have increasing choices about management of their most important renewable resource industry. Tougher regulations on operators certainly are achievable and in some cases highly desirable. One choice they should not make, however, is to hoist unsustainable regulatory policies on the forest products industry. That’s the kind of thinking that helped push the sector to the brink of collapse in the first case.

Steady but persistent approaches to the implementation of regulatory policies have worked well for Nova Scotia in the past.

They seem a prudent way to manage this vital industry in the years ahead.

PPC Peter Woodbridge is president of Woodbridge Associates, a Vancouverbased forest sector consultancy firm. He is an advisor to several forest industry firms in Canada, including Paper Excellence, and internationally. In 2010, he was commissioned by the Province of Nova Scotia to assess the economic impacts of proposed clear cut reductions on the forest industry. His report is available at www.novascotia.ca/natr/ strategy/pdf/woodbridge-may-2011.pdf

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Technology News

Photo credit: Metsa Fibre Oy

SKF expanding network of certified rebuilders for electric motor repair

Metsä Fibre selects suppliers for 1.3 million ton bio-product mill in Finland

L

etters of intent have been signed with the major equipment suppliers for Metsä Fibre’s bio-product mill in Finland. If the company decides this spring to build the proposed mill, Andritz will supply the world’s highest capacity softwood fibreline, as well as wood processing lines, the evaporation plant and recausticizing equipment.

Valmet has been chosen for the recovery boiler, pulp drying line, gasification plant, and lime kiln deliveries. The Valmet agreement also includes a millwide Metso DNA automation system.

The new bio-product pulp mill in Äänekoski, Finland, will be a nextgeneration facility that can convert wood raw material into bio-materials and bio-energy in addition to highquality pulp. It will not use any fossilbased fuels as all of the energy required will be generated from wood.

Start-up of the planned mill is scheduled for August 2017.

Valmet’s delivery would include engineering, procurement, supply and construction management. The planned recovery boiler has a capacity of 7,200 TDS/d (tonnes dry solids per day). The planned pulp drying line will have a trimmed width of 8.25 meters and a capacity of 2,700 adt/d (air dry tonnes per day). The planned lime kiln has a capacity of 1,200 t/d and will be operated by renewable fuel provided by an 87 MW capacity biomass gasification plant. The gasification plant dries bark and gasifies it to “product gas.”

Andritz’s scope of supplies includes: • A complete wood processing plant

26

with three debarking and chipping lines, three stacker-reclaimer chip handling systems, and bark handling.

Each debarking line can process both softwood and hardwood, is designed for world record capacities (pine/spruce/ birch: 470/350/270 m3 solid-over-bark per hour), and includes a de-icing conveyor, a debarking drum (5 x 48 meter), and the world’s largest horizontally fed HHQ chipper, ensuring high capacity without compromising the chip quality.

• A softwood and hardwood fiberline comprising a chip feeding system, a twovessel continuous cooking plant, a new evaporation system for liquor extraction, and seven DD (drum displacer) washers for brownstock washing and bleaching. The softwood capacity of this line will be the highest in the world (3,900 tons per day).

• One of the world’s most energyefficient black liquor evaporation plants with the highest capacity in Europe (1,650 tons/hour). The plant will have seven stages and concentrate black liquor to the very high dry solids content of 85% for efficient combustion in the recovery boiler. In addition, Andritz will also deliver chloride removal systems to enhance the chemical recovery process and to produce liquid methanol, which will be used as a biofuel source.

• A recausticizing plant, which will be the largest in Europe (white liquor production of 16,000 m3/day), with two centrifuges for dregs, slaker-classifier, white liquor disc filter, and lime mud disc filter.

Valmet, www.valmet.com Andritz, www.andritz.com

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Electric motors make frequent appearances in reliability incident reports. For many companies, electric motor failures lead to a continual cycle of costly repairs and unplanned downtime, according to SKF Canada. And, says the company, since 40% to 70% of motor failures are related to bearings, high-quality bearings are key for reliable motors.

SKF Canada recently launched the SKF Certified Rebuilder program for electric motor repair. Four shops have already achieved the certification: GMR Electric motors, Saskatoon; Les Entreprises LM, Montreal; Continental Electric, Edmonton; GPR Industries, Grande Prairie, Alta.

To earn SKF Certified status, rebuild shop employees have to meet requirements in electric motor testing, bearing mounting and dismounting, lubrication and contamination control practices. Certified shops must also meet SKF standards in all areas of motor repair and maintenance, and are regularly audited to assure compliance.

The SKF Certified Rebuilders have access to SKF’s superior collection of parts, tools, and technical support. They’re kept up to date with the latest technologies and best practices. And they’re empowered to perform root-cause failure analyses and troubleshooting. This allows them to quickly, efficiently, and effectively diagnose and fix electric motors.

Several more companies are in the process of becoming SKF Certified Rebuilders and the Canadian network is expected to grow significantly in 2015.

SKF Canada, www.skf.com

ABB joins Industrial Internet Consortium to promote best practices

ABB, a leading power and automation company, is joining the Industrial Internet Consortium, a group of more than 100 companies, organizations and universities working to accelerate growth of the Industrial Internet by identifying and promoting best practices and robust standards.

The Industrial Internet Consortium, or IIC, was founded in March 2014 to drive innovation, develop standards, boost interoperability and ensure security.

ABB will join the IIC starting in 2015 to foster collaboration among technology companies as they seek to establish global standards for the Industrial Internet.

“This gives us more opportunities to influence what is happening in the development of the Industrial Internet,” www.pulpandpapercanada.com

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Technology News said Claes Rytoft, ABB Chief Technology Officer. “The Industrial Internet holds incredible promise to transform manufacturing, energy and resource industries.”

The Industrial Internet reflects the accelerating application of sensors, software and improved communication technology, allowing engineers to leverage enormous volumes of data from industrial systems to boost efficiency.

ABB has for years advanced the Industrial Internet via the company’s control systems, communication technology and industrial sensors. These help customers use data to optimize operations on offshore platforms, in mining and robotics, aboard marine vessels and in the chemical and paper industries.

“The Industrial Internet is transformational – it changes the way we work,” said Dr. Richard Soley, executive director of the Industrial Internet Consortium.

Today, evolving communication technology and lower sensor costs, combined with higher performance of computers, offer new opportunities to collect, evaluate and integrate even more information from industrial facilities to boost efficiency, fine-tune maintenance and trim energy costs.

ABB, www.abb.com

Oil and grease resistance additive receives food contact approval

Archroma has received FDA approval for the use of its new Cartaguard® KST additive in the manufacture of paper and board for food packaging. This PFOA-free additive provides high levels of oil, grease and water resistance to paper and board.

It is also compliant with the

recommendations of the German BfR XXXVI, allowing global market use.

Cartaguard® KST liquid is based on a cationic C6 fluoropolymer which excels at providing a strong and long-lasting barrier to grease and water. Its performance properties and environmental profile make it particularly suitable for use in both size press and wet-end applications to produce fast food boxes and wrappers, soup cube boxes, butter wrap and oil bottle labels.

It is also suitable for use in production of molded pulp plates, cups, etc., and in pet food packaging.

Archroma, paper.archroma.com

Stora Enso Fors Bruk invests in two complete PulpEye systems

Stora Enso Fors Bruk has invested in two complete PulpEye online analyzer systems, including the CrillEye and ExtractEye modules, as well as an upgrade of their first PulpEye system. The company chose this investment because of a need to replace old analysis equipment on its CTMP lines as well as to improve the control of fibre properties and pulp quality for BM 2. In addition, Stora Enso Fors Bruk hopes to save energy by optimizing stock preparation.

“We have been running the PulpEye systems since last autumn and we can see that they meet our high demands,” says Joakim Sundström, project manager Stora Enso Fors Bruk. “We can already see indications how the refiners in our stock preparation influence the pulp.

The results from our CrillEye module look very promising. We have a much better control of our pulp quality now, which secures a more even quality of our folding boxboard.”

The modernized PulpEye system

Tail cutter protected from harsh mill conditions

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PPCMarApr2015.indd 27

PulpEye has helped the mill to take a big step forward in measurement, says Peter Lundqvist, automation engineer at Stora Enso Fors Bruk.

operates on one of two CTMP production lines. One of the new PulpEye systems is installed on the second CTMP line and is equipped with modules for online measuring of fibre, shives, brightness and freeness. The third PulpEye system is installed in the stock preparation area on one of the board machines and includes the CrillEye module for crill measurement, making it possible to calculate tear, tensile and burst index as well as Scott Bond and density online, according to PulpEye. All three PulpEye systems work according to the PulpOnTarget concept, which is based on the calculation module ExtractEye. In addition, Stora Enso Fors Bruk has bought an RMEye unit which is used to calibrate concentration meters in an efficient way at different measuring points in the process.

Stora Enso Fors Bruk is one of the largest folding boxboard mills in the world.

PulpEye, www.pulpeye.com

In 2014, GL&V initiated a development project to improve and modernize its wet-end tail cutter equipment.

The new design has a totally enclosed and pressurized drive section that protects the motor and clutch assembly from the harsh mill environment. The drive section is also skid mounted and easily removable for off-machine maintenance.

The FlexTrim tail cutter is also flexible and adaptable. It has several control options, optional travel speeds, and is adaptable to any machine width.

Four of these improved units have recently been sold, installed and commissioned and have provided GL&V with positive customer feedback.

GL&V Pulp and Paper, www.glvpulppaper.com March/April 2015 PULP & PAPER CANADA

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Technology News

Mechanical Pulping Highlights from PaperWeek Canada 2015 Brightness control for a two-machine newsprint mill

Micro-nano fibrillated cellulose show promise for enhancing TMP

Manipulating bleaching chemicals manually to meet paper brightness targets can be difficult and organizations will prefer to err on the high side, resulting in over bleaching, at a cost, say the authors of “Benefits of Implementing a Paper Brightness Control System in a 2-machine Newsprint Mill.” Jean-François Hamelin, process optimization engineer with Metso Automation, presented the brightness control paper at PaperWeek 2015, on behalf of two co-authors from Resolute Forest Products’ Clermont, Que., mill, Jean-François Labranche, paper machine 5 superintendant, and Roger Leroux, mill manager.

In the case of a mill with two paper machines fed with the same pulp, one more difficulty arises: maintaining two different targets on each machine using common bleach addition points. For Clermont, a control application was designed to use four manipulated variables in a multi-variable predictive control (MPC) strategy to maintain brightness targets on both machines and minimize the use of bleaching agents. Details of the controller design, control performance, and benefits are described in this paper.

The Clermont mill uses hydrosulfite as its only brightening agent.

The manipulated variables included in the control strategy are: • leveling tank hydrosulfite dosage; • paper machine #4 hydrosulfite dosage; • paper machine #5 hydrosulfite dosage; • TMP main lines secondary refiner hydrosulfite dosage.

The controlled variables included in the control strategy are: PM5 brightness, PM4 brightness and TMP pulp brightness.

The feedforward variable is leveling tank inlet brightness.

The first difficulty comes from dealing with a long process delay, noted Hamelin. In such situations, it is imperative to have information about the amplitude of incoming disturbances, he said. In this application, this problem was solved by installing a Metso Cormec pulp brightness sensor to provide a reliable incoming brightness signal.

Another major problem related to the brightening process is the non-linear process gain between hydrosulfite dosage and brightness increase, Hamelin explained. As hydrosulfite dosage increases, its effective gain decreases significantly so it is important to have an accurate estimate of the current gain from the bleaching curves.

The authors conclude that the brightness control system at the Resolute Clermont mill has helped to significantly reduce overbrightening. Statistics from running “on control” are compared to baseline conditions from the previous year, which also had a similar grade distribution. Performance of the system was compared to the same period during the previous year to avoid the effects of seasonal variations on over-brightening. On PM4, the comparison of baseline versus “on control” shows a 47 % reduction in over-brightening average with a similar standard deviation. For PM5, baseline versus “on control” statistics show a 58 % reduction in over-brightening average with a lower standard deviation.

Savings generated by keeping paper brightness closer to target are expected to result in a return on investment of seven months.

For this project, real time optimization was used to further reduce over-brightening and to keep the bleaching operation in an efficient operating zone. Use of a feedforward pulp brightness signal along with real-time delay and gain adaptation allowed the controller to keep brightness closer to target and reduce over-brightening, therefore reducing bleaching costs.

The possibilities for upgrading TMP pulp and paper with micronano fibrillated cellulose have been explored by a group of researchers at Université de Québec à Trois-Rivières.

Some results of this work were presented at PaperWeek Canada 2015. Upgrading Thermo Mechanical Pulp with Micro-Nano Fibrillated Cellulose at Pilot Scale by Fabrice Roussière, Mohamed Ali Charfeddine, Jean Paradis, Michel Schenker, Patrick Gane and Patrice J. Mangin looks at whether it is possible to produce at pilot scale a structured paper made out of TMP and micro-nano fibrillated cellulose (MNFC).

MNFC is a fibrous material with high barrier and mechanical properties, but the authors identified some processability hurdles, such as water retention and fibrils dispersion. When included in the bulk of the paper, MNFC was expected to affect mechanical properties, whereas if included as a coating, it was expected to alter barrier properties.

The pilot paper machine at Innofibre was used for this project.

MNFC was processed through a GL&V Hydra-Sizer curtain coating device on the fourdrinier table. The MNFC was provided

by Omya. It is produced by a grinding process involving bleached eucalyptus fibres and ground calcium carbonate.

The researchers found that when applied as a coating, there was no distinct boundary between the TMP and the MNFC. The addition of a low fibrillation grade MNFC (L-MNFC) strongly decreases the air permeability of the sheet. They also noted that an L-MNFC layer does not improve elastic modulus in the machine-direction, but cross-direction elastic modulus increases significantly with the presence of L-MNFC. Also, the TMP-MNFC structured papers show significant improvement of the resistance to bending in both directions.

The authors conclude that pilot trials have demonstrated the feasibility of L-MNFC addition on the top surface of a TMP base paper.

When the Hydra-Sizer is positioned after the top former, it appears to cause no trouble in the downstream process.

The water addition at the end of the fourdrinier table is easily absorbed by the vacuum system, they report.

In their paper, Upgrading Thermo-Mechanical Pulp with MicroNano Fibrillated Cellulose: Influence of Fibrillation on Paper Sheet Structure and Properties, Mohamed Ali Charfeddine, and his co-authors Fabrice Roussière, Jean-Francis Bloch, Cathy Ridgway, Patrick A.C. Gane, and Patrice J. Mangin, described a TMP sheet structured by adding MNFC during papermaking.

MNFC was added as a layer with different basis weights at different positions in the thickness of the paper (z-direction).

The project used two grades of MNFC supplied by Omya: H-MNFC (high-fibrillation level) and L-MNFC (low-fibrillation level).

The authors found that paper z-structuration with MNFC is a promising approach to manufacture new 100% TMP (+CaCO3) packaging grades with improved mechanical and barrier properties.

They noted that 6 g/m² of H-MNFC addition (10% of the paper basis weight) reduces the air permeability up to 98%.

Also, MNFC addition improves mechanical properties in the cross direction, more so with the high fibrillated grade (H-MNFC).

PPC

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Bio-Economy

The world’s first wood-based renewable diesel biorefinery has started commercial production in Lappeenranta, Finland. UPM Lappeenranta biorefinery is based on a hydrotreatment process developed

by UPM, and produces approximately 120 million litres of renewable UPM BioVerno diesel per year..

Petri Kukkonen, head of the UPM biofuels business, explains that the start-up phase of the biorefinery began in early autumn 2014, and has included the customary challenges of a new process and production system.

The UPM BioVerno diesel is produced from crude tall oil, a residue of pulp production. A large portion of the raw material comes from UPM’s own pulp mills in Finland.

UPM has a sales agreement with NEOT (North European Oil Trade), a wholesale organization of oil and biofuel products.

UPM operates in several business areas: biorefining, energy, labels, paper and plywood.

UNB receives funding for biofuels research

Photo courtesy of Schlumberger Technology.

UPM begins commercial production of wood-based diesel

CelluForce is working with Schlumberger Technology, a specialist in the oil and gas sector, to develop new applications for cellulose nanocrystals.

CelluForce to explore oil and gas applications for nanocellulose CelluForce has received a contribution of $4 million from Sustainable Development Technology Canada (SDTC) to optimize the extraction process of cellulose nanocrystals (also called nanocrystaline cellulose or NCC) from dry wood pulp and develop applications for its use in the oil and gas sector.

“World-class research led to the development of this ground-breaking extraction process and placed Canada at the leading edge of NCC research,” stated René Goguen, acting president of CelluForce Inc. “This announcement by SDTC sets the stage for the pre-commercial development of applications that will not only support Canada’s forest sector but also the oil and gas sector.”

CelluForce is a joint venture of Domtar Inc. and FPInnovations. It operates a nanocrystalline cellulose (NCC) demonstration plant at the

Domtar pulp and paper mill site in Windsor, Que. This current project will further improve and optimize the NCC process developed by CelluForce to extract nanocrystalline cellulose from dry wood pulp. It will also investigate additional applications for the oil and gas industry, such as cementing using this renewable forestry resource.

According to the SDTC funding announcement, NCC may play a role in suspension methods for extracting oil out of the ground. When NCC is added to the suspensions, they remain cohesive even under extreme conditions. As well, the addition of NCC reduces the volume of water and pressure needed to carry out the extraction.

CelluForce’s partner in this project is Schlumberger Technology Corp., a supplier of a wide range of services to the oil and gas sector.

The University of New Brunswick will receive $306,200 over three years to work on new technology to help Canada develop better, cleaner and cheaper renewable fuel.

UNB’s Dr. Ying Zheng, Canada Research Chair in Chemical Processes and Catalysis, and her team will work in collaboration with Queen’s University at Belfast and Atlantic Hydrogen Inc. to build on previous catalyst discoveries that improve biofuel quality and yields, and reduce the energy consumption involved in refining them. This research will allow small biorefineries to use this new technology as a cost-effective solution to produce the next generation of biofuels used in diesel and gasoline.

Dr. Zheng’s project is called “Integrated plasma catalytic processes for hydrogen-free upgrading of biomass-derived biofuels to hydrocarbon fuels.”

These investments are the result of the 2014 Strategic Project Grants competition, administered The company has initiated a three-year project with packaging company by the Natural Sciences and Engineering Research ecoXpac, with the collaboration of Innovation Fund Denmark and the Technical Council of Canada (NSERC).

University of Denmark, to develop a biodegradable and bio-based bottle made Also receiving funding under NSERC’s 2014 from wood fibre, to be known as the “Green Fiber Bottle.”

Strategic Project Grants competition is Robert BradAll materials used in the bottle, including the cap, will be developed ley of Universite de Sherbrooke in Quebec, for using bio-based and biodegradable materials – primarily, sustainably sourced his project, “Predicting wood fibres – allowing annual allowable cut in In co-operation with www.cleantechnology.ca the bottle to be respona changing world.” sibly degraded. PPC

Carlsberg will develop wood-fibre beverage bottle

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Unpack the power of Maximyze for packaging. ®

Let Buckman help you improve sheet strength and increase productivity.

Buckman announces new Maximyze enzymatic technology for recycled packaging. It can significantly improve sheet strength and drainage, so you can increase machine speeds. With a customized Maximyze program you can reduce fiber costs, steam consumption, transportation costs and your environmental footprint too. No wonder it’s an EPA Presidential Green Chemistry Challenge Award winner!

Find out more. Contact your Buckman representative or visit buckman.com.

Better drainage Production on a recycled linerboard machine was limited due to drainage. Buckman’s Maximyze application improved drainage, so machine speeds could be increased by as much as 100 mpm. Steam use was reduced 8%, and CO2 emissions were reduced by 1806 metric tons per year.

Reduced energy A core and tube producer wanted to increase production, have greater flexibility in its fiber selection and reduce energy use. Buckman applied Maximize to the pulper, which conditioned the fiber faster with less refining energy, preserving fiber strength. Speed increased 10%. Refining energy decreased 30%. And tensile strength increased from 20 to 26 kgf/15mm.

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