By A PPI Special report
BRUSSELS,
Oct. 10, 2011
(RISI) -
Yet again we have had a truly global response to the PPI Awards, with numerous entries from all continents and in all categories. Clearly this industry is beginning to understand the power of achievement, and that how being recognised is a tonic for all the people who work so hard in the pulp and paper business, from the top management offices to the paper machine halls and beyond.
Over the next few weeks, we'll review the individuals, companies, mills and products that have been nominated for an award in this year's PPI Awards 2011.
This week, as we look at the nominations for the Business Strategy of the Year Award and the Water Efficiency Award, many mills and companies are turning their attention to sustainable practices and consumer demands for green products. Of course, reducing water consumption is not just good business, it's also a necessity for many of the world's mills. Expanding into new markets and developing brand new products is another common theme, proving the days of the traditional pulp and paper mill may be numbered.
Business Strategy of the Year Award
Domsjö Fabriker, Sweden
After producing various grades of pulp since 1903, a slate of new owners bought the Domsjö mill in 2000 with the single goal to turn it into a biorefinery. Through investment and R&D, the reborn facility has become one of the few biorefinery centers in the world based on wood as the raw material. Using a strategy of "Make more from the tree," Domsjö now focuses on turning as many of the wood components as possible into profitable products, with the rest slated for use in energy production. One of its products is specialty cellulose that can be used in viscose fabrics, medical tablets, and paint and heat protection for space shuttles. Another is a biogas that is sold for steam and electricity production throughout Sweden. Building on Domsjö's development success, other companies like AkzoNobel, Sekab, MoRe Research, and Övik Energi are working at the Domsjö site to develop their own biorefinery techniques and applications. Investing in further development of wet and dry cellulose, Domsjö is preparing to expand its business in other areas of textiles and energy. After its first decade as a ‘new' company, Domsjö wants to take its ‘biorefinery' to the next level and take every advantage of the world's growing demand for green.
Domtar, Canada
One of North America's largest pulp and paper producers, Domtar believes it must break out of the traditional mold to remain a viable business in the economy of tomorrow. This year, growth took the lead in the company's ‘Perform, Grow, Break Out' strategy. Acquisitions in fiber-based products with strong demand profiles and investments to its existing assets are two potential avenues, as the company begins looking to expand in India and China. Early this year, Domtar announced it would open a paper converting, sales and distribution business in Southern China in 2012. But this outlook would not have been possible without the results of the last two years, as Domtar spent its time building a firm financial foundation. Upgraded to investment grade status by both Standard & Poor and Moody's in the last 12 months, Domtar was added to S&P's 400 Mid Cap Index in 2011 as a recognition of the company's reduction in long-term debt and increased earnings. With this support, Domtar looks to broaden its view beyond its core business and outside the North American market.
FutureMark Paper, USA
On the back of a $250 million upgrade to create one of the world's most advanced deinking plants, FutureMark decided to reinvent its mill to provide a highly differentiated and valued green product. Taking a customer-focused approach, FutureMark began creating a specific preference for its brand by selling to marketing and sustainability executives, not just traditional paper buyers. Highlighting the mill's use of a third less energy and 40% less water than a comparable mill, FutureMark also provided runnability reports showing how their paper performed as well or better than the average virgin sheet. In the last two years, FutureMark has gained 50 new major accounts with companies known for their commitment to sustainability, and is improving its market share. Production at the mill went from week-to-week to a schedule filled with months of advanced orders. With several new improvements planned to increase efficiencies and further reduce environmental impact, FutureMark expects to be the most attractive partner to customers who value recycled paper and sustainable business practices.
Södra Cell, Sweden
Over the last few years, Södra Cell has made its business by thinking outside the box, away from a commodities-based approach to pulp and towards innovation and new markets. Diversifying its portfolio to include bioenergy, Europe's largest market pulp producer has embraced the concept of the pulp mill as bio-refinery, supplying electricity, biofuels, pellets and wood residues as green energy sources. Södra Cell also recently began production of two high-value pulps; DuraPulp, a patented bio-composite, and a textile dissolving pulp. New R&D projects, with brands such as Foam Pulp and Nano Pulp, are investigating new pulp-based materials and finding ways to use pulp in novel ways, from biodegradable bike helmets to wall partitions and bubble wrap. In a strategic approach that includes new products and markets, as well as efforts to increase value for their existing customers, Södra Cell is announcing its intention to be the market pulp producer of the future.
Water Efficiency Award
AbitibiBowater, Mokpo Mill, South Korea
Producing more than 800 tons/day, Mokpo has achieved a fresh water consumption rate of less than 8,000 tons/day. Using old newspapers as feedstock, the de-inking facility has been recognized as one of the most efficient newsprint paper mills in the world, housing one of the fastest paper machines in operation in Asia. Water recirculation is done through four separate dissolved air flotation systems, two located as part of the newsprint production process and two as part of the waste water treatment plant. With demand increasing for recovered fiber, Mokpo is constantly seeking areas to improve its overall water consumption.
BILT Graphic Paper Products, Bhigwan Unit, India
As the biggest fine coated paper mill in India for over a decade, Bhigwan realizes that water conservation is the cost-effective and environmentally sound alternative to reduce its demand for water. With a strategic goal of doubling capacity in the next two years, the mill both reduced its water usage and found ways to increase its water resources in several areas. Through improved water treatment and reuse, as well as increasing machine speeds to decrease water consumption, Bhigwan has decreased its overall water use by 38% per m3/ton of paper. New water resources have been integrated with a rainwater collection system and a community water conservation awareness program. In return, Bhigwan has invested over $130,000 to supply treated water for local farms in the areas adjacent to the mill.
Bio PAPPEL International, Prewitt Mill, USA
Situated 7,000 feet above sea level produces its own set of water challenges to generate 225,000 tons of recycled linerboard per year. Because of its single water source and lacking a permit to discharge water, Prewitt has needed to go further with water reclamation and reuse than a traditional mill and in the process made the mill a zero-liquid discharge facility. In addition, the mill achieves one of the highest water efficiency levels for the paperboard grades it produces, as indicated by data from TAPPI and Metso as well as internal benchmarking. Certified FSC and SFI, Prewitt faces a daily task to produce "clean water" from an inconsistent and dirty feed, but at the same time has achieved a 30% reduction in water consumption over the last ten years.
Caraustar, Carotell Paperboard, USA
Carotell takes advantage of a 100% closed water system that recirculates, filters and reuses all of its process water. All of the water used in forming and pressing is returned to the water system, and the only process water eliminated from the mill is through evaporation in the drying process. Within the system, water temperatures are kept near optimal temperatures, saving on energy costs to heat fresh water. Other benefits include reducing the costs required for treating waste water and discharge permits for the mill. Through its closed system and day-to-day management to maintain a good water balance, especially in the production of some specialty grades, Carotell has found an optimum balance between costs and a high environmental standard, and eliminated concerns on any potential containments being introduced into the public water system.
Smurfit Kappa Group, Los Reyes Mill, Mexico
Located near Mexico City, environmental conditions and water scarcity means production activities at the Los Reyes paper mill thrive by focusing on processing water instead of consuming it. In 2007, Los Reyes developed a water management program, using a combined approach of personnel and systems, whose main objective was to reduce fresh water consumption for every m3/ton of paper produced. Employees are trained on water management and awareness, and regularly spend time looking for water inefficiencies in their work areas. The mill's water system was also improved, including optimizing the white water system and increasing the amount of water reused in production. Since then, Los Reyes has reduced its fresh water usage by 57% and now returns more than 95% of the fresh water used for production after being cleaned in the on-site water treatment plant.
To find out more about the PPI Awards for 2011 please visit: The Pulp & Paper International Awards 2011
