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A targeted approach to produce energy-efficient packaging materials from high-yield pulp, TAPPI Journal August 2025

ABSTRACT: Unlike fossil-based plastics, wood-based packaging materials can be produced in an ecofriendly manner using wood chip residuals from sawmills and pulpwood. To produce high-yield pulp like chemithermomechanical pulps (CTMPs) for paperboard and liquid packaging, it is crucial to reduce the electric energy consumption during fiber separation. The ultimate objective is to revolutionize paperboard production by achieving a middle-layer CTMP process that consumes less than 200 kilowatt-hours per metric ton (kWh/t), significantly improving from the current 500•600 kWh/t energy demand. Optimizing the CTMP impregnation process of sodium sulfite (Na2SO3) in wood chips is crucial for achieving uniform softening, ideally at the fiber level. The properties of the fibers are significantly affected by the content of lignin sulfonates within the walls of the fiber and the middle lamellae. In this study, we employed in-house developed X-ray fluorescence (XRF) techniques, validated by beamline measurements, to map the distribution of sulfonated lignin within fibers. It also seemed possible to enhance the surface area of lignin-rich pulp fibers while losing minimal bulk by refining them with well-optimized low consistency (LC) refining. We aimed to achieve a highly efficient separation of coniferous wood fibers by co-optimizing the sulfonation and the temperature in the preheater and chip refiner. Additionally, we explored how lignin’s softening behavior and potential crosslinking influence subsequent unit operations, including pressing, peroxide bleaching, and drying, following the defibration process. In defibration during chip refining, the maximum softening of wood fibers is preferred to maximize fiber preservation and minimize energy consumption. However, optimizing the stiffness of finished pulp fibers is preferable to reduce bulk loss during paperboard production. It can strive to optimize processes to develop stronger, lighter, and more sustainable composite packaging materials. Reducing environmental impact and electric energy can help create a more sustainable future.

Liansheng Pulp & Paper Pioneering a Green Tissue Future

Liansheng Pulp & Paper's successful entry into the tissue market demonstrates how strategic technology partnerships drive operational excellence and cost reduction. The company achieved 98% machine efficiency and 5-10% long fiber savings using Andritz PrimeLine W 2000 tissue machines with advanced suction pressure rolls and high-consistency refining systems. This case study highlights critical performance benchmarks for plant managers, including 42% post-dryness achievement, energy consumption reduction through heat recovery systems, and production flexibility across 30 different tissue grades. The partnership exemplifies ROI-focused decision making, combining environmental stewardship with competitive market positioning through innovative manufacturing technologies that enhance both sustainability metrics and bottom-line results.

A targeted approach to produce energy-efficient packaging materials from high-yield pulp, TAPPI Journal August 2025

ABSTRACT: Unlike fossil-based plastics, wood-based packaging materials can be produced in an ecofriendly manner using wood chip residuals from sawmills and pulpwood. To produce high-yield pulp like chemithermomechanical pulps (CTMPs) for paperboard and liquid packaging, it is crucial to reduce the electric energy consumption during fiber separation. The ultimate objective is to revolutionize paperboard production by achieving a middle-layer CTMP process that consumes less than 200 kilowatt-hours per metric ton (kWh/t), significantly improving from the current 500•600 kWh/t energy demand. Optimizing the CTMP impregnation process of sodium sulfite (Na2SO3) in wood chips is crucial for achieving uniform softening, ideally at the fiber level. The properties of the fibers are significantly affected by the content of lignin sulfonates within the walls of the fiber and the middle lamellae. In this study, we employed in-house developed X-ray fluorescence (XRF) techniques, validated by beamline measurements, to map the distribution of sulfonated lignin within fibers. It also seemed possible to enhance the surface area of lignin-rich pulp fibers while losing minimal bulk by refining them with well-optimized low consistency (LC) refining. We aimed to achieve a highly efficient separation of coniferous wood fibers by co-optimizing the sulfonation and the temperature in the preheater and chip refiner. Additionally, we explored how lignin’s softening behavior and potential crosslinking influence subsequent unit operations, including pressing, peroxide bleaching, and drying, following the defibration process. In defibration during chip refining, the maximum softening of wood fibers is preferred to maximize fiber preservation and minimize energy consumption. However, optimizing the stiffness of finished pulp fibers is preferable to reduce bulk loss during paperboard production. It can strive to optimize processes to develop stronger, lighter, and more sustainable composite packaging materials. Reducing environmental impact and electric energy can help create a more sustainable future.

Valmet to Increase Resource Efficiency Through Digitalization at Klingele Weener Mill in Germany

AF&PA Commends EU Decision to Extend Deforestation Regulation Deadline to December 2025

AFT to Supply Stock Preparation and Approach Flow System Rebuild to a Major Customer in Asia-Pacific

Trinseo and RWDC Industries Announce PHA Dispersion Partnership 

Agreement builds on ongoing efforts to optimize PHA dispersions for paper and paperboard barrier coating applications. 

A Systems Thinking Approach: Institutional Memory Loss in Pulp and Paper Industry, TAPPICon25

Unlock the Future of Tissue at TAPPICon 2025

TappiCon 2025 returns to Minneapolis May 4-7, delivering advanced technical insights and leadership development opportunities for experienced pulp and paper professionals. This premier conference offers mid-career managers and technical leaders access to cutting-edge research, benchmarking data, and networking with industry executives. Attendees gain specialized knowledge to drive ROI initiatives, enhance team performance, and advance their careers through expert-led sessions, standards committee participation, and executive briefings. The event provides practical solutions for operations optimization, sustainable manufacturing practices, and emerging technologies that directly impact plant efficiency and profitability for experienced professionals seeking deeper specialization.

TAPPICon Insights Help Tissue Professionals Stay Ahead of the Game