Pulp & Paper Industry | 2024 PLI Report

PULP AND PAPER INDUSTRY MARKET AND PRODUCTION LINE INTELLIGENCE

Overview EPTDA was founded as the European Power Transmission Distributors Association in 1998 on the initiative of a group of power transmission and motion control (PT/MC) industrialists who believed in bringing together PT/MC distributors and manufacturers on one unique platform. It has since become the largest organisation of PT/MC distributors and manufacturers in EMEA and is one of the most powerful and respected B2B executive platforms for the industry worldwide.

EPTDA’s mission is to strengthen its members in the industrial distribution channel to be successful, profitable, and competitive in serving customers to the highest standards. The association takes great pride in its values which focus on being a premier community for qualified members through open dialogue and mutual respect; acting with integrity, honesty, and fairness; and ensuring continuous growth and learning.

EPTDA continually strives to develop relevant tools for its members, helping them stay competitive in a constantly evolving marketplace and business environment. As part of the development of tools and resources for members, this document is designed to add value to their commercial understanding of specific markets and production line processes. This document, on the Pulp and Paper industry, follows reports on the Soft Drinks industry, Confectionery, the Automotive industry, Material Handling, Recycling, Aggregates, Forestry, and most recently, Bakery.

Purpose of this document The purpose of this document is to provide distribution management and their sales forces with market and production line intelligence on the Pulp and Paper industry. This document explores trends, identifies products used in the production of pulp and paper products, clarifies key challenges, and considers the opportunities for distributors and how these can be capitalised, commercially.

This document has been divided into three parts:

1.

Industry Overview

Pages 4-11

This first section provides an introduction and overview to the Pulp and Paper industry and gives key background information, market intelligence, and major players within the industry. It has been organised as follows: a. Definition, segments within the industry, and market share b. Market size and coverage c. European sales data and evolution d. Current and future market trends e. Overview of challenges f. Key producers g. Major machine & system builders

2.

Production Line Intelligence

Pages 12-25

This section illustrates the production and processing of pulp and paper, with a fully detailed production line schematic, so as to provide an understanding of what is involved and where the opportunities lie. Key customer challenges, major product groups, typical maintenance, and improvement projects are identified throughout the line, as well as highlighting potential areas of commercial opportunity for the distributor. This production process, whilst being typical, does not represent how all types of paper are produced.

This is because actual plant processes may vary according to the production method of pulp - such as mechanical or chemical pulping - the type of paper produced - for example, high-quality print paper or cardboard - as well as whether the pulp for the production of paper or board is produced on site or recycled pulp is brought in from elsewhere.

3.

Use of this Document

Pages 26-27

The opportunities within Pulp and Paper, both for MRO and OEM distribution, are significant – a minimum combined ‘scale of opportunity value’ (SOV) of 280M€ has been estimated as available for distribution of Power Transmission products in the pulp and paper aftermarket. The final section proposes how the document could be used and provides open-ended questions that can be asked of prospective customers in order to reinforce the knowledge gained in parts one and two and to maximise the available opportunities.

3

PART ONE

Pulp and paper industry overview Definition, segments within the industry and market share Paper has been in existence for over 2,000 years and continues to compete successfully with digitalisation, advanced plastic and composite packaging materials with paper or paper-based products being an everyday reality for many in developed societies.1 Pulp, traditionally, and still primarily, used for papermaking can be produced from virgin fibres – through chemical or mechanical processes, or through the repulping of paper for recycling.

In Europe, wood is the primary source of raw material with paper for recycling accounting for around 50% of the fibres used. In some cases, straw, hemp, grass and other cellulose-bearing materials are also used.2 Type

The pulp and paper industry can be segmented in a few ways – by pulp type, pulp production method and by output. Often, the fibres used to produce certain types of pulp will influence the output. For example, the use of softwoods such as pine, cedar or spruce, contain long strong fibres that are best-suited for packaging due to its strength. Whilst hardwoods like oak, birches and beeches contain shorter fibres and are more appropriate for writing, printing and tissue paper.

Examples Cedar

Pine

Softwoods

Oak

Hardwoods

Uses Spruce

Birches

Beeches

Long strong fibres for packaging paper Short fibres for writing, printing and tissue paper

Difference in fibre structure between mechanical and chemical pulping

Production of pulp, by type (2021)8 Mechanical pulping

WOOD

Wood Consumption2

OTHER FIBRES Other Fibres3 Consumption

112.3 NON-FIBROUS MATERIALS

PULP

Raw Materials

Collection of Paper for Recycling

11.4

37.3 Market Pulp Imports

PAPER FOR RECYCLING

Non-Fibrous Materials Utilisation

Total Pulp Production1

55.4

Market Pulp Exports

Imports of Paper for Recycling

5.7

8.7

Exports of Paper for Recycling

6.9

2.2 Utilisation of Paper for Recycling

Total Pulp Production

PAPER AND BOARD

40.3

50.7

Paper and Board Production

Paper and Board

90.6 Paper and Board Imports

Paper and Board Exports

4.8

20.2 Paper and Board Consumption

75.2 Newsprint 3.4

Other Graphic Papers UM 3.7

CM 3.3

UW 6.1

CW 2.4

Case Materials 31.6

Other Packaging P&B CB 6.1

Wrapp

2.8

OPP 4.4

Paper and Board Consumption = Production + Imports from outside Cepi - Exports to outside Cepi3 UM = uncoated Mechanical - CM = Coated Mechanical - UW = Uncoated Woodfree - CW = Coated Woodfree CB = Carton Board - W = Wrappings - OPP = Other Paper and Board for Packing = S&H = Sanitary and Household

4

S&H 7.4

Other P&B 3.9

There are two main ways in which pulp is produced – mechanically or chemically. Mechanical pulping creates weaker paper products such as newsprint paper, towelling and tissue etc. as the fibres are substantially damaged in the pulping process, although, because both lignin and cellulose fibres remain intact, the yield of paper to volume of wood is greater than that of chemical pulping.4 Mechanical pulping can be separated into refiner mechanical pulping (RMP) and thermomechanical process (TMP). Both involve counter-revolving discs grinds wood chips into smaller chunks and individual fibres. The main difference between the two processes is that the rotating disks in RMP operate under a stream of water whilst in TMP, the wood chips are first steamed under pressure for several minutes before being passing through the rotating discs.

On the other hand, chemical pulping breaks down the chemical structure of the lignin from the cellulose fibres using chemicals.

The wood chips are placed in a pressure cooker, a “digester”, and the lignin and hemicellulose are removed – separating and cleaning the fibres. Due to this, fibres have greater flexibility making chemical pulping particularly suitable for stronger paper products such as paper board.

5%

Chemical pulping

There are also two major techniques in chemical pulping: kraft pulping, which is most popular and accounts for most of the pulp produced using this method, and sulphite pulping. In kraft pulping, wood chips are treated with a sodium sulphide and sodium hydroxide solution and are then “digested” for a few hours at an elevated temperature and pressure. Sulphite pulping involves treating wood chips with sulphite or bisulphite salts of sodium, calcium, potassium, magnesium or ammonium. This process is not well suited to woods with low extractive contents such as pine trees and produces less yields than the kraft process.

A comparison of mechanical and chemical pulp:5 Figures in Million Tonnes

before proceeding to the mechanical pulping process. The pulp yield can reach as high as 94%7, making it more productive than chemical pulping (approx. 80%) but due to the use of chemicals is still lower than that of mechanical.

Mechanical pulp

Chemical pulp

Cost

Low

High

Yield

Approx. 90%

Approx. 50%

Energy

Intensive

Energy generation from black liquor

Brightness

Low

High

Yellowing

High

Low

Opacity

High

Low

Strength

Low

29% 66%

More recently, as technology in the industry has advanced over the last 50 – 60 years, chemi-mechanical (or semi-chemical) pulping has also increased in popularity. This is where the raw material e.g. wood, is processed by a light chemical treatment

Other

The output of the pulp industry can be divided into four segments: Graphic paper, packaging, hygiene and household paper, and other industrial or special purposes.

Production of pulp products (2022)9 9% 5%

High

While chemical pulping does produce higher strength paper, there are many disadvantages such as its increased costs and lower yield. Over the recent years, an especially big concern has been the troublesome waste products that are produced during the chemical pulping process. Since sulphur compounds are used to break down the woodchips, often compounds such as hydrogen sulphide and dimethyl sulphide are emitted into the atmosphere.6

Mechanical and chemimechanical pulp

Chemical pulp

26%

Packaging

60%

Graphic paper

Other

Hygiene and household paper 5

Aside from graphic paper, there are many uses of pulp: Graphic paper

Packaging

- Newsprint - Uncoated paper - Coated paper

- Containerboard (cardboard) - Food wrapping - Paper bags - Paper cups

Hygiene and household paper

Other

- Tissues and napkins - Paper towel - Toilet paper - Medical papers - Diapers and baby wipes - Filters

- Car filters - Shoes and handbags - Binding agents in food and pharmaceuticals - Labels and stickers

Pulp can also be segmented according to the fibrous materials used to manufacture pulp: 1. Wood fibres e.g., pulpwood, wood chips or residues 2.

Non-wood and other fibres e.g., straw, bamboo, grasses, cotton fibres, rags and other textile wastes 3.

Paper for recycling e.g., recycled paper, paperboard and fibreboard

Did you know?

Europe is the world's second-largest producer of pulp and paper, manufacturing nearly a quarter of global production.10

The energy and raw materials required for the pulp and paper industry is intensive with high capital costs, but the industry does have a reputation in resource efficiency and innovation. It is a pioneer in making the EU low-carbon bioeconomy an industrial reality. This is because paper is the most sustainable and recyclable packaging material available in the world today.11 As a result, this PLI report will explore the pulp and paper industry with a focus on mechanical or chemi-mechanical pulping and its application of recycled pulp and paper-based goods.

Market size, coverage and sales evolution

1% 1% 5% 24%

52%

22%

In Europe, the pulp industry was estimated at a value of 95 billion euros – an increase of nearly 15% from the previous year (2020). In 2022, the European production of pulp decreased by 3.7% with a total output of nearly 36 million tonnes. This was largely influenced by strikes at the beginning of 2022, increased worldwide inflation, high energy costs forcing many mills to temporarily close and the impact of the Russia-Ukraine conflict.

Despite overall decline in the production of pulp, consumption and demand for pulp-based products continues to show resilience with production of paper reaching 84.8 million tonnes in 2022.16

Africa

Americas

Asia

affected by the EU Single Use Plastics Directive. The pandemic also saw a surge in demand for household tissue and towel products, with consumers placing a newfound premium on personal hygiene. The recycling of paper has also significantly improved in Europe, exceeding 50 million tonnes in 2021 for the first time. In fact, among the European industries, “the pulp and paper sector remains in the leading position for its recycling performance, use of renewable energy, energy efficiency and sustainable sourcing”.17

European pulp production by country (2021)18

350000000

Rank

Country

Production value

1

Sweden

19,774,860

2

Finland

19,280,000

3

Russian Federation

15,231,000

4

Portugal

5,424,000

5

Germany

3,958,721

330000000

6

France

3,311,000

7

Spain

3,077,783

8

Austria

2,925,133

320000000

9

Poland

2,900,000

10

Czechia

1,621,278

340000000

310000000

300000000

290000000

2012

2013

Europe

Oceania

The rise of e-commerce, especially during the COVID-19 pandemic helped boost the paper and packaging market, while it also benefited from becoming a solution for other industries

Global production of pulp (2012-2021)12

6

Production of pulp, by region (2021)15

Even though graphic papers have continued to decline, there has been a shift over to packaging and tissue segments especially during the pandemic, which have caused the pulp and paper production to continue to grow. The pulp and paper industry’s global market size reached 351.5 billion USD in 2021 and is expected to reach 380 billion USD by 2023, growing at a CAGR of 4% from 2022 to 2030.13 The US, Brazil and China are the top three producers of pulp in the world, with Europe representing nearly a quarter of global pulp production. The increase can be attributed to consumer trends for example the demand for convenience and concerns over plastic packaging waste and its implications on the planet and overall sustainability.14 Transport and industrial packaging also exhibit room for growth where there is a need to close the gap between a sustainability choice of a fibre-based package versus lightweight plastic packaging.

2014

2015

2016

2017

2018

2019

2020

2021

11

Slovakia

1,539,370

12

Norway

1,206,000

13

Belgium

796,290

14

Italy

460,094

15

Bulgaria

410,569

16

Estonia

335,000

17

UK

227,000

18

Bosnia and Herzegovina

160,000

19

Slovenia

86,000

20

Switzerland

72,139 7

Europe is the second largest consumer and producer of paper in the global market, with recycling paper-based products to help achieve sustainable goals a key trend in the market.19 The global average consumption of paper is 55kg per person per year; however, when looking at a region-by-region basis, there are quite a few differences. For example, North America consumes four times higher than the world’s average at 215kg, and in Western European countries almost double at 147kg, while in Africa, per capita consumption is about 7kg.20

paper-producing industry worldwide. The two largest paper and paperboard producers in Europe are Germany and Sweden. This is due to Finland, Sweden and Germany having the largest forestry coverage in Europe, and as a result, pulp and paper industries in Europe. Approximately 65% of Sweden and Finland’s land is covered in forest, while Germany is one-third forest-covered.21 The consumption of paper and board strongly recovered after the lifting of many pandemic-related restrictions. It reached a level higher than in 2019, before the COVID-19 pandemic.22

In 2020 the pulp and paper industry accounted for 23% of global paper and board production in 2020, making it the second-largest

Paper and board production by region (2020)23

Paper and board production, by country (2021)24

2% 6%

17%

26%

6% 6% 11%

7% 19% 8%

10%

10%

Europe Latin America

North America

Asia

Rest of the World

Germany

Italy

Sweden

Finland

France

Spain

Poland

Austria

Rest of Cepi countries

Recycling Rising environmental concerns are seeing consumers and manufacturer shift their preferences to more ecological paper packaging solutions. Cosmetic, food and Fast Moving Consumer Goods (FMCG) companies are continuously engaging with paper manufacturers to develop advanced paper packaging solutions to meet their commitments towards sustainability. For instance, in 2019, L’Oréal group, in association with Albea Group, launched paper-based cosmetic tubes. In 2019, Nestle S.A. started to launch its products in recyclable paper packaging as a part of the company’s commitment to make 100% of its packaging products recyclable by the end of 2025. This is expected to bolster the pulp and paper market growth.25 Helping to propel the industry with its commitment to recycling is the European Paper Recycling Council (EPRC) which has the “twofold aim of improving recycling and increasing efforts to remove obstacles hampering paper recycling in Europe”. The EPRC is committed to reaching a 76% paper recycling rate by 2030.26

25%

47%

Current and future market trends

In 2021, 71.4% of all paper and board consumed in Europe was recycled (57.1 million tonnes).27 Furthermore, helping to create a circular bioeconomy, recycled paper is often used as the pulp for newsprint, facial tissue, toilet tissues and cardboard. The paper products, after being checked for contaminants, are shredded down into scraps and then mixed with water and chemicals to further break down the paper scraps into fibres – leaving you with pulp that is used to make recycled paper.

The industry initiative 4evergreen is a cross-industry alliance perfecting the circularity of fibre-based packaging to contribute to a climate-neutral and sustainable society. In comparison to the EPRC, the 4evergreen alliance has a goal to raise the overall recycling rate of fibre-based packaging to 90% by 2030.

To do this, 4evergreen helps provide design recommendations for more easily recyclable packaging, guidance on improved collecting and sorting of fibre-based packaging for recycling, and the evaluation of packaging’s recyclability in mills.28 One of the challenges facing the paper manufacturing industry is contamination. If a paper is contaminated with other materials such as food or plastic waste it can make it difficult to recycle and can reduce the quality of the recycled product. This contamination can occur at any point in the recycling process, from collection to processing and can result in additional costs for the industry.

In order to improve recycling rates and reduce contamination this may involve investing in new equipment and processes to improve the quality of recycled materials.29 As with recycling, another challenge is the lifespan of recycled paper and how often it can be repulped (it has been estimated that paper can be recycled on average 4 to 6 times). Over time, the fibres weaken and shorten as a result of the recycling and repulping process, and more virgin pulp must be introduced into

8

paper production to maintain the strength and quality of the fibre. This means that the production of recycled pulp and paperbased products is reliant on the continued production of virgin pulp and paper-based goods. Without the input of virgin fibre, the production of paper would cease after roughly 6 – 18 months, meaning a continual input of 35 – 65% fresh wood fibre is needed depending on the type or grade of paper manufactured.30

Environmental sustainability In addition to recycling, the industry is looking at how it can reduce the amount of water consumed in it’s production of pulp and paper-based goods. To manufacture A4 size paper sheets, for example, manufacturers need around 20 liters of water31, making it the single largest industrial coonsumer of water in western countries.32 Beyond just the production of pulp and in turn paper-based goods is also the initial planting and management of trees used for supplying the raw material to make the pulp.

To help with efficiency, suppliers of timber and wood will often choose the quickest growing species which has the by-product of requiring vast amounts of water.33 Awareness of this huge consumption has led to advancements in technology behind the production of pulp and paper-based goods to ensure 91% of water used is returned to the environment, cleanly and safely.34 Although paper can be made from (wood) fibres without the use of water, as demonstrated in a prototype

by Seiko Epson Corporation with their papermaking system called PaperLab, the scalability of this new technology has not yet been realised.35

Trade barriers and supply of raw material There is an increasing share of exports outside of the EU but tariff barriers and protectionist subsidies for rival goods create an uneven playing field. Taxes and export duties imposed by non-EU countries on wood exports raise concerns. For example, fibre raw material represents the highest share of production costs, and so its availability at affordable prices is crucial for the sector.

The pulp and paper industry already uses between 33-40% of all industrial wood traded globally,36 but in addition demand for domestic EU wood supplies by end-users such as bioenergy firms is also rising. This means there is competing demand for wood from these industries, ultimately affecting supply and demand.

Often manufacturers of pulp and paper-based goods rely on their own ‘managed forests’ to supply the wood and other fibres used in their products. This works towards a sustainable supply where as trees are cut down, several are planted or naturally regrow in its place, at a rate to keep the environment stable.37 An alternative to traditional wood fibres is also providing the pulp and paper industry opportunity to mitigate cost and availability of raw materials. Fibres from more renewable sources such as straw, corn stalks, grasses and fast-growing crops like bamboo and hemp are becoming more popular alternatives, as well as other non-fibre materials such as polypropylene and cellulose fibres. Using these alternative fibres also provides high-quality, environmentally friendly pulp and paper products that meets the increasing consumer demand for sustainable products.38 9

Digitalisation

Number of Cepi* paper and pulp mills in Europe, by type (1991-2020)41

Although the digital revolution has not left the pulp and paper industry obsolete, with the demand for online sales growing, there was a transition from using paper for printing to using materials for packaging.

As a result of this many mills have adopted digital technologies to improve their communication with customers and suppliers.

Critical to optimising the performance of plant operations and reducing quality variations in pulp and paper manufacturing is proactive and accurate process control. Smart technology is being adopted by the pulp, paper, and packaging industries; this digital

transformation in manufacturing reduces the consumption of raw materials, and process variability, drives down costs, increases throughput, and gains a competitive edge with customers.

For example, the ProcessMiner AI-enabled platform delivers process improvement recommendations and optimal control parameters in real-time to your pulp and paper production line.

Through predictive machine learning and artificial intelligence systems, online recommendations are sent for autonomous proactive control. The platform ensures reductions in cost, scrap, and defects commonly encountered in pulp and paper manufacturing processes.

1400 1200

1006 822

800

0

Ranking

Company

Revenue (USD billions)

Head-quartered in

1

WestRock

21.3

United States

2

International Paper

21.16

United States

3

Smurfit Kappa Group

13.7

Ireland

4

UPM

12.5

Finland

5

Stora Enso

12.5

Finland

6

Oji Holdings Corporation

12.2

Japan

7

Mondi

9.54

United Kingdom

8

Nine Dragons Paper Holdings

9.1

Hong Kong

9

Nippon Paper Industries

7.5

Japan

10

Sappi Limited

7.3

South Africa

766

742

600

296

233

218

2000

2005

200

Global key producers (2022)39

1991

Paperboard

172

155

2010

2015

152

2020

Pulp

*Confederation of European Paper Industries (Cepi)

Over the last two decades the number of pulp and paperboard mills has steadily declined, despite resilience in demand for pulp-based products. High energy costs and an intense and resource-intensive production process has led to mills closing frequently.

Major machine & system builders ABB | Switzerland | global.abb.com42

Valmet | Finland | www.valmet.com45

With over 100 years’ experience in machinery for the pulp and paper industry, ABB manufacturers complete end-to-end solutions required for pulp, paper, board and tissue manufacturing.

Providing technology solutions for pulp and energy production, Valmet delivers complete production lines, machine rebuilds and process components for board, tissue and paper production.

ANDRITZ | Austria | www.andritz.com43

Types of mills used in the pulp and paper industry40 As seen in the bakery industry, mills can be ‘market’ producers, supplying pulp to industries for further application, or can be produced ‘in-house’ or integrated into the entire production line of pulp or paper-based goods.

Type of mill

Functions

%

Specialist paper mills

Manufacture products with different specifications in small quantities

35%

Tissue and hygiene paper mills

Manufacture tissue grades, wet wipes, wadding and cellulose

27%

Packaging paper mills using recycled fibre

Manufacture traditional corrugated boxes and cores

20%

Specialist packaging paper mills

Manufacture many products but often focus on luxury product packaging

11%

Printing and writing mills (including newsprint)

Manufacture paper for general printing, magazines and newspapers, graphics and high-grade packaging

7%

10

1076

1000

400

Key producers in the pulp and paper industry

1274

ANDRTIZ operates across a number of industries, including hydropower, metal working and steel, and pulp and paper, supplying complete systems, equipment and services. Other supporting areas of expertise include power generation, environmental technology and equipment for the production of nonwovens, dissolving pulp, panelboard and recycling plants.

Bellmer | Germany | www.bellmer.com44 Bellmer designs, customises and manufactures equipment and complete production lines for the production of paper, board and specialty fibre products. Nearly all machines are manufactured in Germany, whilst headboxes, pulpers and formers are produced in Finland.

Voith Paper | Germany | www.voith.com46 A full-line supplier, Voith builds machinery for new lines, rebuilds and entire machine sections for the production of all paper grades. Machinery is offered through the XcelLine range, while Voith’s AquaLine helps papermakers reduce fresh water consumption throughout the production line. Voith has also developed a complete range of ventilation and digital solutions to increase efficiency and management throughout the entire papermaking process.

11

Production of pulp and paper Process

Process

PART TWO

Pulp and paper production line market intelligence Infeed and preparation 1. Collection of timber

2. Debarking

3. Chipping

4. Sorting

5. Storage

Timber or pulpwood logs used for the production of paper will typically come from forests managed for this specific production process. More trees will be planted than harvested to ensure sustainable growth.

The logs then go through de-barking drums where bark is stripped by knife, drum abrasion or a hydraulic barker.

Once the logs have been debarked they enter a wood chipper where rapidly rotating disc plates containing knives cut the logs into small woodchips to exact measurements.

The chips are passed through vibrating screens to ensure only correctly sized chips pass through. Dust, undersized and oversized chips are rejected.

Once the chips are screened to ensure they are the same size they are sent to storage silos, until ready to be sent for pulping. They are stored with an agitator to keep the chips in suspension.

More and more paper Did mills are relying on you recycled pulp brought in know? from elsewhere.

Sometimes this recycled pulp is used on it's own or combined with virgin pulp for added fibre strength.

Thermo Mechanical Pulping (TMP)

12. Screening

11. Refining

10. Infeed

9. Digester

8. Washing

The fibre is screened to make sure they are all separated from each other.

The rejected fibre is sent back for further refining.

Two giant metal grinding plates, one static and one rotor with intricate grooved patterns are rotating at approximately 1500 RPM. These shred the chips into papermaking fibres while the pattern ensures the fibres are separated in a lengthwise direction.

The water in the chips vaporises due to the heat and high pressure and fed into another screw feeder for further refining into pulp fibre.

The uniform, heated chips are fed into the Thermo-mechanical Pulping (TMP) refiner using a high-pressure screw feeder.

The chips are heated again with gas to soften the ligned (the glue which holds the wood fibres together), making it easier to separate the wood chips.

The chips are exposed to hot steam to even out the moisture content before being passed through a washer to ensure stone and twig nuts are removed. The high-quality chips float to the top where a paddle pushes them over to a water pump used to push the chips up to de-watering screws. Here, the chips are separated from the water.

12

7. Infeed of recycled pulp [or recycled paper] It is at this stage that any pulp produced from recycled paper/ waste is brought in as part of an 'in-line' process.

6. Transportation From the storage silos, the chips are transported on conveyor belts.

13

Production of pulp and paper Process

Process

PART TWO

Pulp and paper production line market intelligence Bleaching

Washing

13. De-watering press

14. Bleaching chemical added

15. Chemical reaction

16. Washing

17. De-watering

18. Rejection/storage

The pulp fibre is transported to the bleaching plant where water is removed by cylinders with blankets.

The dry pulp is transported via a screw conveyor to a small refiner where bleaching chemicals are added.

The mix of chemicals and pulp is pumped to a bleaching tower where the chemicals and pulp react for a designated period of time.

The bleached pulp is transported from the bottom of the bleaching tower along a screw conveyor to a vat where water is added to wash away the bleaching chemicals.

The chemicals and water are removed by cylinders with blankets. The pulp is soaked and de-watered again to ensure all chemicals are completely removed.

Ejected chemicals (black liquor) are harvested for re-use, while the bleached pulp is sent to storage silos.

Coating

Paper-making

23. Winder

22. Quality scanning

21. Calendaring

20. Head-box, wire, pressing, shoe press and drying

19. Dilution

The paper is wound on the jumbo reel or tambour.

This is then cut into smaller reels and customer specifications (diameter, width of reel and number of reels or tons), ready for transportation to the customer.

Using a Quality Compliance System (QCS) monitor which travels back and forth across the sheet, key paper properties (weight, brightness/whiteness, thickness or calliper, and mineral fillers) are assessed.

A hard heated metal surface presses the paper against a softer backing roll to help make the paper smooth and glossy and to keep a consistent sheet thickness. Some rolls may be thermorolls which can be heated up to 260°C by steam-heated oil.

The pulp is pumped between two forming fabrics woven in a special pattern from thin polyester threads. Jets ensure that the pulp is spread evenly over the forming fabrics.

The pulp is diluted with water and pumped into a de-airater to remove any air bubbles. The pulp will consist of roughly 1% pulp and 99% water.

A bottom and top wire help drain the water from the pulp, forming a fibre web.

The fibre web still contains around 80% water, so the fibre web is compressed between two felts. When released, the felt sucks the water from the web like a sponge.

The fibre web is pressed several times before undergoing a final round in the shoe press. Here, the pressure time is extended to increase the dryness so that the fibre web now only contains 50% water.

Supported by drying fabrics, steam-heated cylinders slowly dry the fibre web to its final moisture content to 7% water and 93% fibre (depending on desired water-fibre ratio) at a temperature of 135°C.

14

15

Production of pulp and paper

Key products and opportunities

Key products and opportunities

Explaining the opportunities and projects Key critical projects within the pulp and paper industry have been highlighted along the schematic to make it easy to identify which areas of the process have the most opportunity.

Infeed and preparation

3. Chipping

1. Collection of timber

2. Debarking

Key product groups

Opportunities / challenges

Key product groups

Opportunities / challenges

 Bearings  Belts  Chain – bush conveyor chain and drive chain  Couplings

 Roller chain, sprockets + conveyor replacement – 250–300 euros per mill, every year.  Papermakers usually only use the parts of trees other commercial industries won’t e.g., sawmill waste and forest thinning.  Operating in a harsh external environment, subject to weather.  Replacement of drive/ bush chain every 2–4 years.

 Bearings – cylindrical roller bearings, filament bearings, spherical roller bearings, split bearings and housing units  Belts – synchronous belts, rubber conveyor belts, v-belts and belt drives  Conveyor chain and melting conveyors  Couplings – fluid couplings  Fans  Gear drives  Grease  Hose assemblies – fittings and tubes  Hydraulics  Knives  Locking assemblies  Power packs  Pumps  Solid steel units

 Operating in a harsh external environment (outside weather, debris, shocks, water) means spike chain/ toothing will wear more frequently and need to be replaced every 2-3 years.  Kicker drives see heavy shock load and this can lead to shaft failures. Replacing gearboxes with a belt box can improve reliability and lifetime.  Before the loading drums, logs are run through melting conveyors where they are rinsed with water so that sand and other debris is sorted.  Logs tend to be transported by chain, and then when softer/lighter may move over to belt.  Some drives are chain-based and can be replaced with synchronous belts to give a more efficient, lower maintenance and longer lifetime option.  This is heavy duty application, that if goes down, the entire plant must stop. Requires high-quality, reliable products to ensure uninterrupted performance.  Bark removed from logs can be used at the mill or sold to other power-generating companies for burning as a biofuel.

1

2

3

Key product groups

Opportunities / challenges

 Couplings  Drive chains  Belts – friction and synchronous belts  Hoses, fittings and tubes for hydraulic systems.  Locking assemblies

 Some drives are chain–based and can be replaced with synchronous belts to give a more efficient, lower maintenance and longer lifetime option.  Kicker drives see heavy shock load and this can lead to shaft failures. Replacing gearboxes with a belt box can improve reliability and lifetime.  Usually big gear couplings or high elastic couplings are used because of high speeds and torque.  Very high shock loads during this process, including vibrations, dust.

4. Sorting Key product groups

5. Storage Opportunities / challenges

Key product groups

 Belts – synchronous and  Belts slipping or mis-tracking due to high moisture content in chips v-belts can cause spillage in the load zone.  Drive and conveyor chains  Can be hard to clean.  Plummer blocks  Lower capacity belts can be used to drive pumps and transport systems.  Risk of dust explosions.  Dust and environmental contamination and result in dirty belts and increased wear. Belts with high wear resistance are recommended if not correctly guarded.  Opportunity for replacement with roller chain – self-cleaning with use of sprockets for greater lifetime.  Wood chips are also supplied as a by-product from sawmills.

4

 Belts – friction and synchronous belts  Elevator conveyor  Scraper chain  Slewing ring Opportunities / challenges  Belts for conveyors and air handling units. Use of synchronous belts eliminates maintenance over drive lifetime.

5

Thermo Mechanical Pulping (TMP)

6

7. Infeed of recycled pulp [or recycled paper]

6. Transportation

Key product groups

Opportunities / challenges

Key product groups

Opportunities / challenges

 Belts – v-belt drives  Hoses, fittings and tubes for hydraulic systems  Industrial hose

 Operating in a wet and dirty environment so nickel-plated pulleys are used to increase durability (from 1-2 years to more than 5 years). SOV: Saving from reduced replacement.

 Bearings – insert ball bearings, pedestal and flanged bearings  Belts – friction, synchronous and rubber conveyor belts  Gearboxes  Idlers  Lubricators  Motors  Pulleys - drive and idler pulleys

 Rubber conveyor belts are usually hot welded or hot glued into the machine on site.  Belts for conveyors and air handling units. Use of synchronous belts eliminates maintenance over drive lifetime.

16

7

17

Production of pulp and paper

Key products and opportunities

Key products and opportunities

Thermo Mechanical Pulping (TMP) continued 8. Washing

9. Digester

10. Infeed

Key product groups

Opportunities / challenges

Key product groups

Opportunities / challenges

Key product groups

Opportunities / challenges

 Bearings – spherical and roller bearings  Belts – synchronous, friction and v-belt drives  Chain – special stainless steel conveyor chain  Couplings – sleeve couplings  Hoses, fittings and tubes for hydraulic systems  Locking devices  Paddle drive and screws  Shrink discs  Well-sealed plummer block housing made of steel

 Belts slipping or mis-tracking due to high moisture content in chips can cause spillage in the load zone.  Can be hard to clean.  Drives need good resistance to water and chemicals to minimise degradation.  Use of aggressive chemicals – carbon chains cannot be used and seals of bearing houses and units, for example, must be the right type and material for durability.  Vertical installations.  Shrink discs and sleeve couplings are used in pressure diffuser to attach two coaxial shafts. Customers require high precision and quality.  Annual replacement of locking devices and shrink discs. SOV: 10-20k€ depending on size, type and volume.  Operating in a wet + dirty environment so nickel-plated pulleys are used to increase durability (from 1-2 years to more than 5 years). SOV: Saving from reduced replacement.

 Belts – friction and synchronous belts  Hoses, fittings and tubes for hydraulic systems

 Sensitive to chip thickness  The wood chips are usually cooked (in a digester) in an acid solution for up to 8 hours to dissolve out the lignin and expose the plant fibres. This pulp produced is referred to as "wood free".  Use of synchronous belts eliminates maintenance over drive lifetime.  More commonly used by plants using wood chips.

 Bearings – spherical roller bearings and cylindrical bearings  Belts – friction and synchronous belts to drive high pressure screw feeder due to high loads  Couplings – gear couplings  Drum  Fluid couplings  Gear box + wheel  Hoses, fittings and tubes for hydraulic systems.  Pillow blocks

 Use of synchronous or friction belts eliminates maintenance over drive lifetime.  Usually gear couplings between gear box and screw feeder.  Gear wheel (36 module) replaced every year (4 wheels with 2 pillow blocks each).

SOV: 15k€ replacement per wheel and 25k€ replacement of pillow blocks.  SOV: 10k€ per coupling (safety) to ensure motor doesn’t break.  Not standard size roller bearings.

SOV: 3-4k€ per bearing.  Gearbox replacement. SOV: 50k€.

11 8

9

10

11. Refining

12. Screening

Key product groups

Opportunities / challenges

Key product groups

Opportunities / challenges

 Couplings – gear (steel)  Belts – friction and synchronous belts to drive shredder due to high loads  Hoses, fittings and tubes for hydraulic systems

 It's important to maintain a consistent supply of pulp stock to the paper machines as pulp vessels represent a level measurement challenge due to thick and sticky material, high temperatures, steam in the vapour space, agitation and corrosive and abrasive effects of the slurry.  This process generates high-temperature and high-pressure steam which can be recovered as energy.  Gear couplings are used because of the needed axial stroke. Some refiners nowadays are upgraded to take the stroke with splines inside refiners, therefore no stroke on couplings needed and steel laminae couplings can be used to upgrade.  High axial movement of shafts.

 Belts – friction and synchronous belts to drive screen  Hoses, fittings and tubes for hydraulic systems

 TMP/Kraft fibres are much stiffer than many other grades of pulp, which give key benefits to the paper sheet. (e.g., they provide paper for books with high bulk and stiffness properties).

18

12

19

Production of pulp and paper

Key products and opportunities

Key products and opportunities

Bleaching 13. De-watering press

14. Bleaching chemical added

15. Chemical reaction

Key product groups

Opportunities / challenges

Key product groups

Key product groups

Opportunities / challenges

 Bearings – special sealed spherical roller bearings with special coating  Couplings – gear couplings, elongated couplings  Electrical motors  Belts – friction and synchronous belts to drive screws  Hoses, fittings and tubes for hydraulic systems

 Mix of water and chemicals – seals must be the right type and material for durability.  Vertical mounting of bearings/shaft with sorters  Change from gear couplings (which requires grease to lubricate steel on steel, although quality of grease has improved and could last up to 5 years) to laminate couplings (which doesn’t requires greasing). SOV: 3k€ replacement per coupling.  Motors sit outside of the machine so have to compensate for the couplings being inside (incl. temperature difference).

 Bearings – taper and spherical roller bearings  Belts – friction and synchronous belts to drive screws  Hoses, fittings and tubes for hydraulic systems  Washer drums

 Belts – friction and synchronous belts  Locking devices

 Annual replacement of locking devices.

SOV: 2–10k€ depending on size, type and volume  Locking devices are used to attach pulper rotors. This requires high precision and must meet technical needs of speed and torque transmission. Occasionally they will require special plating or customised options.

Washing

15

13

16. Washing

14

Key product groups

Opportunities / challenges

 Couplings – gear and elastic couplings  Belts – friction and synchronous belts for conveyors  Hoses, fittings and tubes for hydraulic systems  Torque limiters

 Typically gear couplings or elastic couplings, sometimes combined with torque limiters

17. De-watering Key product groups  Belts – friction and synchronous belts to drive screws  Hoses, fittings and tubes for hydraulic systems

18 17

16 18. Rejection/storage

20

Key product groups

Opportunities / challenges

 Belts – friction and synchronous belts to drive conveyors

 Black liquor is recovered to produce high-pressure steam used throughout the production line.

21

Production of pulp and paper

Key products and opportunities

Key products and opportunities

Paper-making 19. Dilution

20. Head-box, wire, pressing, shoe press and drying

Key product groups

Key product groups

Opportunities / challenges

 Belts – friction and synchronous belts to drive screws

Head-box  Belts – friction and synchronous belts to drive conveyors  Hoses, fittings and tubes for hydraulic systems in head box and rolls Pressing and shoe press  Bearings – spherical roller bearings: for press and suction rolls, particularly narrow tolerance for the running accuracy of the inner and outer ring  Belts – friction and synchronous belts  Couplings – gear with steel laminae  Hoses, fittings and tubes for hydraulic systems and for actuating the shoe and the nip Dryer  Bearings – carb bearings, flange bearings and housing, ceramic ball bearings and spherical roller bearings (specially coated and sealed)  Belts – dampening, friction and synchronous belts  Drying fans and pillow blocks  Hoses, fittings and tubes for hydraulic systems  Motors  Pillow block bearing units

Head-box  Runs at speeds of 100 km/h (2000 litres/second)  About 3,300 tons of water is removed every hour Pressing  Here, depending on the pressing method, a distinction is made between simple presses, suction presses, shoe presses and multiple presses.  There is a trend to replace installed gear couplings with steel laminae because of maintenance.

Shoe press  In the shoe press, the paper is pressed against a hydraulically moved metal shoe by a soft rotating roller. This prevssure forces the water out of the paper and then transports it away with the aid of the dampening belts.

Drying  The paper runs over numerous heated drying cylinders, guided by endless dryer fabrics (formerly drying felts). The drying cylinders are steam-heated (steam temperature depends on paper type, thickness, speed and number of drying cylinders).  Spherical roller bearings with a case-hardened inner ring and larger radial internal clearance are usually used due to the extreme temperature fluctuations, especially in the heating phase.

20

21

19

 The high temperatures of the heated steam are transmitted to the bearing seats and place correspondingly high stresses on the rolling bearings. In order to keep bearing temperatures as low as possible, the cylinder journals through which steam flows are insulated.  The drives (several within the machine) must synchronise. Historically gear couplings were used but due to increased speeds, backlash and maintenance issues there is a trend to use laminae couplings between motor and cylinders.  The dryer is the longest part of the paper production line - consisting of 31 steam-heated cylinders (may repurpose steam created earlier in the refiners)  The drying process is completed so that the paper web has a moisture content of 5 to 10% at the end.  The paper web can run through the paper machine at a speed of up to 1400 meter/minute.  Every 9 months, ceramic bearings are checked and replaced. SOV: 1.5k€ per bearing.

22

23

Washing 21. Calendaring

22. Quality scanning

23. Winder

Key product groups

Opportunities / challenges

Key product groups

Key product groups

 Belts – friction, synchronous and toothed belts  Couplings – gear or disc with steel laminae  Gearbox  Hoses, fittings and tubes for hydraulic systems  Rollers

 Rollers are often driven by toothed belts (V-belts) which serves as a connection between the gearbox and the roller.  Coating: depending on the type of paper and requirements, base papers, for example, are further refined. In this process, the two-dimensional fibre structure of the base paper with its irregular surface structure is covered by the uniform application of a pigment layer.  There is a trend to replace installed gear couplings with steel laminae or disc couplings because of maintenance.  Opportunity for refurbishment of big bearings.

 Belts – friction and synchronous belts  Chain – stainless-steel chain to go over width of belt

 Belt – synchronous belts for winding machines  Chain – plate belt chain and floor conveyor chain  Couplings – precision couplings  Floor conveyor outfeed  Locking devices  Shrink discs  Winders

22

Opportunities / challenges  Up to 100,000 metres of paper can be wound (weighing about 40 tons).  Plate conveyor chains consist of one conveyor chain on the left and one on the right and they are connected with a trough metal plate, this can be several hundred meters long from the paper machine to the paper roll storage.  Servo drives (precision couplings) to better respond to the paper tensioner feedback are also a trend in winders.  Large heavy duty locking devices are used to mount winder rollers. Customers require high quality, precisely made items with tight tolerances. Annual replacement of locking devices and shrink discs. SOV: 20k€.

23

Production of pulp and paper

The approximate value of PT aftermarket sales in the European pulp and paper industry

‘Putting it all together’

280M euros

Infeed and preparation

Bleaching

Recycling

Thermo-mechanical Pulping (TMP)

Washing

Proportion of replacement products Safety ring / DIN parts / measuring and hand tools / screws Linear technology Pneumatics

5%

Machined parts and components e.g., sprockets, connectors and pulleys Work safety equipment

Coating

Couplings

2% 3% 3%

6% 7%

40%

Paper-making

Belt and chain

Bearings

9%

10% Seals and lubrication

15%

Hydraulics

*In addition there will be significant spend on motors and gearboxes, although this may be directly supplied by manufacturers.

24

25

PART THREE

Using this document to develop business The following provides the reader of this document, particularly focused on Sales Team members, with some questions to help to generate revenue from this Production Line Intelligence overview and so develop your business within the Pulp and Paper industry.

For many of these questions you may already know the answers.

Others might be used on a regular basis when you visit customers and prospects in other industry sectors. It is meant as a resource to act as a prompt and reminder allowing your business to fully capitalise on this market intelligence and production line information.

There are three parts that deal with: 1. The preparation – this provides questions to consider before going to the site, in two sections:a. Detail of the company – is it part of a chain, or is it an independent? b. Who are the people to be seen – technical, engineering, maintenance?

2. The meeting itself – what to ask during the meeting to understand the concerns, needs, requirements and potentials.

3. The follow up – questions to ask or to reflect on, at the end of the meeting or afterwards

The actual meeting ‘Producers of the pulp and paper’ Some of the above can be asked during the meeting, but some research beforehand is preferable.

The plant or facility

•

•

•

How old is the plant?

•

How many people do they employ?

•

Do they have their own maintenance engineers?

•

Who makes the purchasing decisions – locally or at Group level?

•

Does this company have other facilities in the region you service?

What are your initial thoughts about the main challenges they are likely to face?

Your opening question …………. tailored to their role?

General •

What do you already know about: – Its size in terms of capacity, output etc.?

– The types of pulp or paper it produces – virgin pulp, recycled pulp, paper, board?

– The paper production process it uses – refiner mechanical (RMP), thermomechanical (TMP) or chemical pulping?

– The production system they use and the manufacturers of those systems?

•

•

What do you want to achieve from the meeting – your goal?

– Exploratory – trying to understand the pressures/ problems they face – starter question – ‘what are the main issues you face in keeping the plant running?’

– Presentation – trying to suggest how your company’s service can help? – ‘these are the services we provide that might help you with those issues’ – Breadth of service – showing that you are not simply a component provider? – ‘energy saving/efficiency’ – ‘full range of MRO products’ – ‘support of manufacturer/suppliers’ What will you fall back on, if your intended goal seems impossible?

– Ensure they know that you are interested/could add value?

– Ensure that they have your name, title, services to hand for the future?

– Confirm that they would be willing to meet you again, in the future?

The people you might meet

•

What is your plan for follow ups to this meeting?

• •

•

What kind of support material do you need to take with you – tailor made to the Pulp and Paper Industry rather/ as well as general information?

•

26

What type of plant are you visiting ?

– Is it a full production facility – that is, from pulping wood to finished paper? – or: – Is it a limited production facility - that is, buying in the pulp – either from wood or from recycled cardboard – then using that to manufacture the end product?

•

Who are you going to see?

What is their role or speciality (production/maintenance/ repair/purchasing)?

What do you know about them already? (hint: search LinkedIn)

•

Do you have existing projects carried out in relation to maintenance or energy management etc.?

– A re existing partners – suppliers or distributors – assisting?

•

What sort of production site is this e.g., pulp mill, paper plant or complete production line?

•

How many production lines are there and what types of products are produced?

•

– W hat type of seasonal production are there (if applicable)?

– How do you deal with the change in product varieties?

– What method of pulping is used e.g., mechanical or chemical pulping?

The most utilised products

•

What are the processes used across the various stages of production (infeed and preparation; bleaching; pulping; washing; paper-making and coating)?

•

•

How are the main machines maintained and repaired (internal team, external team, machine builder service engineers)?

What are the main concerns in relation to type of components that are needed to maintain and improve the line e.g., bearings, chain, hydraulics, pneumatics, etc.?

•

Where is the process most prone to failure or maintenance problems?

Preparing – before the visit The producing company – makers of the ‘pulp and paper’ (End user / Brand manufacturer)

to assist you in this process?

Maintenance, planning and issues •

What sort of regular maintenance does the plant undergo?

– Regular shut-down periods or other?

•

What is the estimated annual spend on maintenance and repair?

•

What are the main issues in relation to maintenance or 'bottlenecks' in the process that affect speed or reliability?

What are the key maintenance/industrial supplies objectives for the facility?

•

What parts are used most on an annual basis?

– W hat are the issues/challenges faced getting those parts?

Suppliers •

What do you value most in relation to a supplier/ distributor like us?

•

What kind of support do you look for from your service providers in relation to planned maintenance?

•

What is your biggest current problem with your aftermarket suppliers?

– H ow do you like your supplier partners to assist?

– W hat are the main issues or concerns in relation to maintenance?

– What are they caused by?

– Are there on-going projects to deal with this?

– Are you using partners – suppliers or distributors –

•

Next steps – C an we come back with a proposal to help you with some of this?

The follow up •

What were the main points you learned from the visit?

•

What are the next steps you need to take, when and how?

•

How and where are you going to store this information – does your company have a CRM system/process?

•

What other types of follow up will you undertake and why?

•

How are you going to use this information for future business, either with this potential customer or others – discussing opportunities within the Company at Sales Meetings?

•

Who in your business do you need to share this information with?

– Do you have success stories to describe? o other members of your team have such – D success stories?

– How can these be replicated?

•

How will you ensure that these follow ups are completed?

27

Acknowledgements Acknowledgements and a sincere thank you to the following manufacturer members of EPTDA for the generosity of the technical and commercial information and advice that they have supplied and which has given real authority to the document.

Also to our technical experts from distributor members of EPTDA operating in this sector, who have provided the concrete examples included in the text and without whose contribution the document would lack its operational and commercial relevance and power for distributors.

Finally to the individual members of the EPTDA Business Intelligence Task Group, who have freely given their advice, guidance and inputs throughout the process of producing this document.

Authored by:

Disclaimer: The costed examples contained in this document are illustrations taken from real practice. They are, however, not predictions of future value achievable from various projects that can be undertaken in this sector. The authors, contributors and EPTDA do not accept any liability for any commercial decisions that may be taken as a result of these examples.

Sources: 1.

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28

European Commission, ‘Best Available Techniques (BAT) Reference Document for the Production of Pulp, Paper and Board’ Ibid.

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