Paper mill of the future: innovations for climate protection
The EU's climate targets are a major challenge for the paper industry, which has high energy requirements. A new initiative is now developing solutions for the paper mill of the future – in an open-ended and interdisciplinary way. This is an exciting project in which we are actively involved as shareholders.
The EU aims to become climate-neutral by 2050 and to reduce greenhouse gas emissions by at least 55 per cent by 2030 compared to 1990. This is an enormous challenge, especially for the paper industry. Although it has a high recycling rate of 79% and was able to reduce its specific CO2 emissions by 36% between 1995 and 2018, However, with a 6.7% share of total energy consumption, it still ranks fifth among German industrial sectors.
The industry is therefore called upon to develop solutions for more energy- and resource-efficient paper production. This is the goal of the Model Paper Mill Initiative. Its goal: climate-neutral paper production by 2050. Its task: to create forward-looking solutions for paper production using new research approaches that – among other things – are expected to save 80% of the energy required in the manufacturing process by 2045.
The Papier Modellfabrik was founded at the end of 2020 as a non-profit limited liability company and supporting organisation with a total of 15 shareholders. 20 companies and more than 100 individuals, associations, and renowned institutes and research institutions are now involved. An innovation centre with a research hall, laboratories and offices is being built at the Düren site near Cologne for the specific purpose of implementing the project. It is scheduled for completion in 2025.
Active participation as a shareholder
For decades, we have been committed to the energy-efficient and resource-saving production of paper and corrugated board packaging, in particular through the use of renewable energies and innovative production technologies. In 2019, we received the World Corrugated Award as the world's most environmentally friendly company in our industry.
Our active participation in the model paper factory as a shareholder is therefore only a logical step for us. Together with all the other stakeholders, we want to take responsibility for the paper industry's achievement of specific climate targets into our own hands. As a shareholder, we have the opportunity to actively drive and shape this process.
No area is left out
We don't yet know what adjustments will be needed to achieve climate neutrality in paper production. However, the task is a broad one, as illustrated by the five primary areas on which the initiative is focusing: in very general terms, the first step is to increase energy and resource efficiency and embed it in the overall system of a sustainable circular economy (overall system and energy).
The focus is also on developing alternative and energy-efficient raw materials, as well as new processes and methods in paper production. Digitisation also plays an important role: the analysis of big data and digital twins should provide new insights and support the development of new raw materials, manufacturing processes and circular processes. And last but not least, the use of natural resources such as wind power for manufacturing processes is also an important topic. In this way, the paper model factory ties in with the German government's national bioeconomy strategy.
Energy generation, processes and raw materials
The issue of energy generation is certainly central to the paper industry, especially the generation of electricity and steam. More than half of the energy required is needed to dry the paper alone. Against this background, our company has laid the foundations for increasingly independent and clean energy production in recent years with our RDF power plant in Weener and by utilising biomass, hydropower, biogas, wind power and photovoltaics. In addition to this, the paper model factory will now develop new disruptive methods in order to tap into energy efficiency potential in the area of processes and procedures - especially as there is now a big question mark over the role of gas as a bridging technology.
In addition to alternative methods of energy utilisation, the initiative also aims to develop new processes as well as alternative raw material properties or chemical additives, for example to dewater paper better and faster. It is about nothing less than rethinking the production of paper and scrutinising every process in the process.
First research projects as early as this year
Seven participating research institutes have now begun compiling the current state of research and production. On this basis, they will then make recommendations for action. The exciting thing is that some of the institutes involved have never had anything to do with paper production before. This should also give new approaches a chance. Four research projects were launched in mid-2022.
All areas will be scrutinised for the establishment of research projects; coordination will be handled by the model factory. As soon as a research project is approved, the companies involved can collaborate on it, usually via a project support committee. Interim reports are then presented to the shareholders' meeting, which takes place twice a year.
"An ambitious project needs a broad network and competent partners. I am therefore delighted that the Klingele Paper & Packaging Group is part of the "Model Factory Paper" project. As a manufacturer of paper and corrugated board packaging for over 100 years, Klingele knows the challenges of the industry. And with its continuous investment in its own sustainability and resource-saving production, Klingele is an excellent project partner with a great deal of expertise. Our common goal with the "Model Factory Paper" is to make the entire paper industry sustainable and forward-looking."
Peter Bekaert, Managing Director Modellfabrik Papier GmbH
Model factory also reduces your CO2 footprint
The Paper Model Factory is not only an exciting initiative with an open outcome, but also a pioneering project to support the EU's climate targets through innovative measures. Not only the companies involved, but the entire industry, as well as society, needs new innovative solutions for the manufacture of products that we all use every day. For the industry and for our company, our participation in the model factory, with its high-calibre network of industry and research, brings enormous advantages:
Medium and long-term technology developments become transparent at an early stage; this enables us to make strategic decisions, for example for investments or new technology projects, with this knowledge. The initiative builds up new technological knowledge through research projects, which should quickly find its way into industry and thus also promote our own competence development. And finally, the paper model factory sends a strong signal that the paper industry is proactively and intensively addressing the challenge of paper production without harming the climate.
And you, as our customer, also benefit from all this, because with paper and packaging produced in an environmentally friendly way, you reduce your carbon footprint.
Implementing innovations and breaking new ground has always been part of our corporate philosophy. We are therefore very pleased to be actively involved in this exciting journey towards a climate-friendly future.
Sustainability is the future.
Klingele takes responsibility for the environment, society and its employees, prioritising recycling, the circular economy and renewable energies – and supports your sustainability goals.
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