Renewable and. Paper. For Media, Packaging, Specialty and Hygiene. ICCA, April 2009

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Reynold Cox
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1 Renewable and Recyclable Materials: Paper For Media, Packaging, Specialty and Hygiene ICCA, April 2009

2 Wood the renewable source for paper Where does the raw material come from originally? Sustainable, managed forest: Natural forests Planted forests 2

Sustainable use By sustainable forestry we

grow back (or grow even more), naturally

natural and planted forests - as a healthy

forest as a living basis for local people

3 Sustainable use By sustainable forestry we mean: Taking only as much wood as will grow back (or grow even more), naturally or thru plantations Keeping forests the natural and planted forests - as a healthy organism by biological diversity Accept forest as a living basis for local people by allowing industrial forestry in all countries 3

CO 2. Sweden is therefore CO 2 -positive.

4 Sustainable forestry in Europe Example: Sweden Swedish forest grows 1% per year due to sustainable forestry. Swedish forest trap 110 million tons of CO 2 per year. Sweden emits altogether 54 million tons of CO 2. Sweden is therefore CO 2 -positive. If all forests s would oud grow like this, the worldwide CO2 problem could be easily solved. 4

5 Sustainable forestry in Brazil Example: Klabin paper and pulp mill FSC-certified since 1998 as the first South American company in the paper sector to manage forests ecologically 90,000 hectares of woodland, 55% of which h are plantation ti forests and 45% natural forest. 5

6 Sustainable forestry in Brazil Example: VCP / IP pulp and paper mill Reforestation of 200,000 ha of steppe within the last 15 years at Tres Lagos Brasil Sustainable forestry contributes substantially to the trapping of CO 2 Reforestation is triggered by the paper industry 6

Forest one of the most important resources

But forests are also an alternative to fossil

As an order of magnitude, we need to consider

world has to be doubled to meet the needs of

7 Forest one of the most important resources Forests are important for paper industry. But forests are also an alternative to fossil fuels. As an order of magnitude, we need to consider that the current wood production around the world has to be doubled to meet the needs of the emerging bioenergy sector. Wood must be used most efficient for the paper industry 7

8 Recovered paper the recyclable resource for paper Pulp mill Natural forest Plantation Recovered paper Integrated mill TMP Stock preparation Paper mill Recycling Incinerator User Retail Processing 8

9 Efficient use of fibers: Recycling of paper Fresh fiber Recovered paper Due to the use of recovered paper, the fibers are used efficiently. ~50% ~50% Paper is distinguished by being a perfectly recyclable material. Today already 50% of the paper produced is made from recovered paper. Worldwide paper production 2007: 394 million tons / year 9

10 Challenge to use fibers more efficient: Increase the recycling quota to 70 % Today Possible Future Szenario in % 50% 197 mio tonnes 197 mio tonnes Fresh fiber Recovered paper 70% 350 mio tonnes 150 mio tonnes 30% Total fiber production 2007 Total fiber production 394 million tonnes / year 500 million tonnes / year

11 Use of recovered paper pays off Energy costs are considerably reduced Cost advantage of fiber raw material (Waste paper) Image gain paper from recovered paper is regarded by consumers as especially environmentally friendly material 11

12 Use of recovered paper lowers energy costs 4,760 1,500 4,000 ~2,400 kwh/t otro electrical primary thermal heat combined heat and power cycle Due to an increase in the use of recovered paper, energy consumption for the paper industry can be significantly reduced per ton of paper produced. 2,500 2, Chemical Pulp TMP ~ * Recycled fiber ~ ** Recycled fiber DIP * Range depending on the desired quality from kwh/t ** Range depending on the desired quality from kwh/t Fibers Source: European Commission Reference Document on Best Available Techniques in the Pulp and Paper Industry 12

13 Pigments as substitute of fibers? ~500 GCC ~ PCC Pigments 4,760 1,500 2, Chemical Pulp ~2,200 TMP Source: European Commission Reference Document on Best Available Techniques in the Pulp and Paper Industry ~240 Recycled fiber Fibers kwh/t otro electrical primary therma heat combined heat and power cycle ~550 Recycled fiber DIP PCC is not much better than TMP in terms of primary energy consumption. GCC is equal to recycled paper in terms of energy consumption. GCC can help to reduce primary energy.

14 Use of recovered paper lowers energy costs of pulp Outlook for 2020 Worldwide paper production [year] 1500 Year 2008: Year 2020: 400 mio tons at 500 mio tons at recycling rate of 50% recycling rate of 70% 1434 Energy consumption to produce pulp [kwh/t] % -20 % Total consumption Electr. energy 0 Mixture ratio fibers [million tons] Mechanical Pulp Chemical Pulp Recycled Pulp 14

15 Paper is environmentally friendly Paper is preferred over plastic and regarded as environmentally friendly Packaging preferences (in %) Perception of paper (in %) Prefer paper 56 USA over plastic 67 China No preference Environmentally friendly Prefer plastic 12 Neutral over paper 9 Harmful to environment USA China Please note: percentage points missing from 100% represent Don t know / Not answered Source: GlobeScan 2008 (Consumer Survey) 15

16 Consumers prefer environmentally friendly packaging Source: BCG Paper and packaged products Disposable products for the home Fresh meats and vegetables Electronics and appliances Health and beauty products Respondents who have never bought green (%) Respondents who bought green in the past but do not currently buy green (%) Frozen food Home furnishing Drinks Packaged foods Toys and games Pet food Restaurants and ready-to-eat meals Textiles and clothing Travel and transportation Financial services Respondents who sometimes buy green (%) Respondents who systematically buy green (%) past but do not currently buy green (%) systematically buy green (%) Being environmentally friendly is tremendously important for paper and packaging from the consumer s point of view Food products Non-food products 16

17 World view of paper supply chain North Fiber belt: fiber growth and pulp production Recovered paper Recovered paper Paper belt: paper production South Fiber belt: fiber growth and pulp production 17

18 But efficient use of wood requires other advanced technologies Challenges of the paper industry: 1. Disposal of rejects 2. Waste water treatment 3. Fresh water availability 4. Reduce of energy consumption of the recycling process 5. Availability of raw materials (Waste paper) 18

Voith Paper integrated recycled paper mill Forest Wood Paper mill Water Metals & Pigments With new environmental technology the yield from recovered paper is no longer critical, because Recovered

19 Voith Paper integrated recycled paper mill Forest Wood Paper mill Water Metals & Pigments With new environmental technology the yield from recovered paper is no longer critical, because Recovered paper Rejects Organic Load in wast water Energy generation Consumer Paper rejects and organic loads can now be used to produce energy. At the same time the water cycles can be nearly closed and fresh water consumption can be reduced significantly. 19

20 Voith Paper integrated recycled paper mill With the integrated recycled paper mill, recycling rate can be increased and the water as well as energy consumption can be reduced significantly. 20

21 Water treatment with the bio-kidney - the core of the integrated mill Anaerobic reactor Biogas Energy recovery from biogas Production waste water Mineral residues Water recirculation Lime trap 21

22 Our vision of future paper production Raw material Increasing the worldwide recycling rate from 50% to 70% Energy Reducing primary energy consumption by half Water Lowering consumption of fresh water to less than 1 liter per kg 22

23 Trends use of recovered paper in paper production: world in millions of tons % 29.8% P&B production Recovered paper consumption 8% 50.0% 51.0%52.8% 43.8% 46.8% 48.1% 48.8% 49.0% 48.7% % Use of recovered paper Worldwide constantly rising portion of recovered paper as raw material for paper production % 50% 45% 40% 35% 30% 25% 20% 15% 10% 5% 0% Source: RISI (Status: Feb 2009), VPT analysis 23

24 Trends use of recovered paper in paper production: regional differences 70% Asia-Australasia* 60% 50% 40% Graphic Latin America Europe 30% North America 20% 10% 0% *including Middle East Source: RISI (Status: Feb 2009), VPT analysis Big differences between the regions

25 Voith Paper pioneer in recycling of recovered paper Steinbeis i Temming: copying paper made of 100% recovered paper Reduction of raw material costs and energy consumption 25

26 Voith Paper pioneer in recycling of recovered paper Leipa-Schwedt: magazine paper made of almost 100% recovered paper Reduction of raw material costs and energy consumption 26

27 Trends use of recovered paper in paper production: regional differences 70% Asia-Australasia* 60% 50% 40% Graphic Packaging & Tissue Latin America Europe 30% North America 20% 10% 0% *including Middle East Source: RISI (Status: Feb 2009), VPT analysis Big differences between the regions

28 Kraft liner vs. testliner tli / corrugating medium machine: Fourdrinier vs. Gapformer 2 x Fourdrinier KraftLiner USA Fourdrinier + sec. HeadBox KraftLiner at USA Gapformer TestLiner / corrugated Medium Europe

29 Fibers costs Recovered paper and wood pulp price development Jan 2002 Feb in US $ / ton selected grades NBHK -mixed species - Canada/US sources delivered d to US* NBSK - Canadian sources delivered to US East Eucalyptus China** Wood Pulp Sorted Office Paper - US average price, domestic sources Mixed paper - US sources to Asia Corrugated Containers / Supermarket Corrugated US average 0 Jan 02 Jan 03 Jan 04 Jan 05 Jan 06 Jan 07 Jan 08 Jan 09 *No figures available for January 2009 **No figures available for January and February 2009 Source: RISI (Status ), VPT analysis Recovere ed Paper

30 Comparison: Kraft liner with testliner / corrugating medium machine Example: 500,000 t/y Kraftliner 100% virgin fibers Testliner 100% OCC Cost difference Fiber Costs 380 $ / to 120 $ / to (today situation) 190 Mio $/a 60 Mio $/a 130 Mio $/a Fiber Costs 500 $ / to 150 $ / to (expected in future) 250 Mio $/a 75 Mio $/a 175 Mio $/a The cost situation ti of 100% virgin i fibers for kraft liner will become even more critical due to the intensifying bioenergy sector based on wood and the expected energy cost tdevelopment

All tissue grades can be made on one swing-type

development completed Chile: First commercial ATMOS

31 All tissue grades can be made on one swing-type machine out of recycled fibers: ATMOS Tissue Paper quality equal to TAD with 80% DIP Energy: 45% less than TAD Easy swing Dry Crepe - ATMOS Commercial development completed Chile: First commercial ATMOS machine in operation No need to be blamed by Greenpeace for TAD offerings 31

32 What we are working on 1. Integrated recycled paper mill 2. Developing recycling technology of the next generation 3. Consistent elimination of toxic chemicals from the system 32

33 What we are working on B&P Supporting the trend to light weight packaging Increasing efficiency and quality through comprehensive process analysis Adapting processing demands for the use of 100% recovered paper Using virgin fibers to fulfill special quality demands 33

34 What we are working on B&P DuoFormer Base II Less energy consumption to produce light weight packaging 34

35 What we are working on B&P Klabin s Monte Allegre MA 1100 mill Klabin s Monte Allegre MA 1100 mill A first class concept for macking liquid packaging board out of 100% virgin fibers 35

36 What we are working on B&P Saica highly efficient machine for testliner and corrugating medium made from 100% recovered paper. 36

37 What we are working on B&P BoostDryer at Klingele Weener (Germany) New drying technology for better quality and less energy consumption

The Implications of a Changing Raw Material Outlook and its Effects on Containerboard Production, Products and Manufacturing in the Future

The Implications of a Changing Raw Material Outlook and its Effects on Containerboard Production, Products and Manufacturing in the Future ICCA/WCO GLOBAL SUMMIT 22-25 May, 2011 Outi Juntti, Pöyry Management