3 INNOVATIONS TO MAKE PACKAGING MORE ENERGY EFFICIENT AND FASTER

At our department in Loenen, we turn old paper into new solid cardboard packaging. In this process, the cardboard machine plays a crucial role. Here, we make old paper suitable as a raw material for new packaging. Hans Kloezeman, Production Manager of the Cardboard Machine at Smart Packaging Solutions, talks about the latest developments and innovations.

Glass, paving stones, parts of an engine block. It is probably not the first thing you think of when it comes to producing new packaging. Yet our operators at the cardboard machine often come across such objects in the bales of old paper that we process into raw material for new packaging.

Hans Kloezeman: “We go through a whole process to turn old paper into a usable raw material again. It starts with processing the bales of old paper that arrive here. Sometimes, in addition to old paper, there is also other waste in those bales. The challenge is to separate the waste as well as possible to recycle as much old paper as possible. We are constantly working to further improve this process. Our goal: extract even more valuable fibers from the old paper and further reduce the energy needed for it.”

“At the cardboard machine, we process the old paper into a sheet of solid cardboard. At the beginning of the process, we use a lot of water for this. Later in the process, the cardboard needs to be 'dewatered'. We do this by pressing and drying.”

 “We recently started using a new hydraulic press to press the water out of the cardboard. The result is visible in practice: the cardboard that come out of the press have less moisture than with the old air-pressure press. The so-called dry matter content is approximately 0.5 to 1% higher than with the old press. That may not sound like much, but it is. This has an impact on the rest of the process. The more moisture the hydraulic press squeezes out, the less energy is needed in the drying process that follows to remove the remaining moisture.”

After pressing it’s time for drying. “We do this by heating the cardboard by passing it over heated cylinders. This generates a lot of waste heat that we could reuse. Therefore, we are investigating the option of a drying hood. This is an insulating hood around the cardboard machine.”

“Here's how it works: the warm air in this hood contains a lot of moisture from the water evaporating from the cardboard. This moisture needs to be removed, so the air is extracted. This warm air can heat the fresh air to be blown in through a heat exchanger. This saves energy because otherwise you would have to heat the fresh air.”

“This can significantly reduce energy consumption. It is expected that just using a drying hood will reduce gas consumption by 20%. Thinking about how we can reuse waste heat symbolizes all the innovations we are making. We always look at how we can increase efficiency and reduce the impact on the environment.”

Since January 2023, Hans Kloezeman has been the Production Manager of the Cardboard Machine at Smart Packaging Solutions. “With previous experience in the paper industry, he finds this field particularly intriguing. When the opportunity at Smart arose, he enthusiastically seized it. As the Production Manager of the Cardboard Machine, he navigates a fast-paced environment: we operate 24/7 and adapt immediately to changes in the process. Of course, the goal is to make as much progress as possible, but ensuring continuity in the process is the main priority.”