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Saica

ZARAGOZA, Spain, Jan. 31, 2015 (Press Release) -Paper, packaging and recycling specialist, the SAICA Group, has announced a spate of investments in Scotland to improve the range of services it offers customers north of the boarder.

This includes new and improved machinery in SAICA's Pack and Paper divisions comprising of a one-of-a-kind ‘conversion' machine that can return high-quality five colour cases in one pass. Following the addition of inter-unit driers SAICA have the capability to manufacture cases including coated liners, full process printing and various varnishes. This investment is helping SAICA Pack to meet the growing demand from clients for highly decorated cases.

SAICA Natur, the recycling arm of the group, has also seen significant investment at its Croy depot. The investment in a new paper sorting line has revitalised the paper processing facilities at the site and the upgrade means that mixed paper collected by local authorities can be separated on the line at a rate of 15 tonnes per hour, a quick and efficient process that helps to maximise the value of the resource.

Additional investment has seen new on-site facilities at the depot and a new collection vehicle.

Ray Hogg, Sales and Commercial Director, SAICA Scotland, said:

"We strive to offer an unrivalled service to our clients and we need to stay ahead of the game to make sure we have the latest market innovations. Our investments in our Scottish operations are helping us to produce even better packs at a faster and more efficient pace."

Keith Verden-Anderson, Scotland Plant Director, SAICA UK, continued:

"This investment shows the confidence we have in our Croy site. The new line has allowed us to expand our team, and we are really pleased to have taken on four new people as a result of the investment.

"It is vital that paper mills are provided with the correct type of paper, and for councils to be able to efficiently sort recycled paper to meet their environmental targets.

"We hope we can continue to grow, and invest in our Croy depot and keep offering our clients an even better service."

The company has pledged continual investment in its operations in Scotland as it strives for excellence and customer satisfaction.

SAICA invests in Scotland to improve range of services to customers

Posted in: Packaging Technology 02/03/2015 - 17:44

ZARAGOZA, Spain, Jan. 31, 2015 (Press Release) -Paper, packaging and recycling specialist, the SAICA Group, has announced a spate of investments in Scotland to improve the range of services it offers customers north of the boarder.

This includes new and improved machinery in SAICA's Pack and Paper divisions comprising of a one-of-a-kind ‘conversion' machine that can return high-quality five colour cases in one pass. Following the addition of inter-unit driers SAICA have the capability to manufacture cases including coated liners, full process printing and various varnishes. This investment is helping SAICA Pack to meet the growing demand from clients for highly decorated cases.

SAICA Natur, the recycling arm of the group, has also seen significant investment at its Croy depot. The investment in a new paper sorting line has revitalised the paper processing facilities at the site and the upgrade means that mixed paper collected by local authorities can be separated on the line at a rate of 15 tonnes per hour, a quick and efficient process that helps to maximise the value of the resource.

Additional investment has seen new on-site facilities at the depot and a new collection vehicle.

Ray Hogg, Sales and Commercial Director, SAICA Scotland, said:

"We strive to offer an unrivalled service to our clients and we need to stay ahead of the game to make sure we have the latest market innovations. Our investments in our Scottish operations are helping us to produce even better packs at a faster and more efficient pace."

Keith Verden-Anderson, Scotland Plant Director, SAICA UK, continued:

"This investment shows the confidence we have in our Croy site. The new line has allowed us to expand our team, and we are really pleased to have taken on four new people as a result of the investment.

"It is vital that paper mills are provided with the correct type of paper, and for councils to be able to efficiently sort recycled paper to meet their environmental targets.

"We hope we can continue to grow, and invest in our Croy depot and keep offering our clients an even better service."

The company has pledged continual investment in its operations in Scotland as it strives for excellence and customer satisfaction.

BRUSSELS, July 1, 2014 (PPI Magazine) - Just one step inside the machine hall at Saica's virtually brand new EUR 360 million containerboard mill at Partington, near the city of Manchester in the UK, reveals to the visitor that this mill is run with precision and pride. Minute attention to detail is simply part of everyday life here. Even the floor shines, and PM 11, the gleaming centrepiece of the whole operation, is possibly one of the quietest paper machines in the business - as well as being one of the most automated.

The mill itself was officially opened just a year ago, and is known in the industry as one of the most advanced, producing some 425,000 tonnes/yr of fluting and linerboard. At full capacity PM 11, which has a width at the reel of 7.7 m, will run at 1,500 m/min producing a weight range from 75 - 135 g/m² and the start up speed was a world record for these grades at 1,100 m/min.

In charge of the whole operation at the Partington site is Pasi Hayrynen, a seasoned Finnish papermaker with vast experience of some of the most challenging start-ups in Europe in recent times - particularly of those machines using 100% recovered paper. Hayrynen's professional experience has taken him all around Europe to countries including Spain and Finland, but his particular experience in the last three years has been in the UK with Palm Paper in Kings Lynn and now at the showcase Saica containerboard mill at Partington.

"10 years ahead of other Automation"

As anybody in the business area of making quality paper from 100% recovered material knows, achieving speed and quality is more akin to an art than a pure skill, and it is a question of getting a lot of things right - all at the same time. And this is where automation comes in. "To achieve the quality that the market demands, and at the speed we demand, we need to take out all the inconsistency which often occurs because of the human element on the paper machine," says Hayrynen. "We like an operating world of ‘no surprises' at this mill".

As one of the pillars of this ‘no surprises' working atmosphere at the mill, Metso Automation supplied the complete automation package for the Partington mill, which has already been described by Saica management as "10 years ahead of other automation". Hayrynen says: "At other mills we tend to use independent suppliers for automation, but Saica Partington was different as we went for Metso (now Valmet) as a machine supplier, so it was decided to use Metso Automation. It works well in this case as the two companies are in close communication with each other and there are all sorts of warranties and guarantees in place."

So how have operations been since the start up, and has PM 11 lived up to expectations? "Like all start ups in my experience, there were one or two teething problems to begin with," says Hayrynen, ‘"however, these problems were outside of Metso's scope of delivery.

"As far as the PM 11 goes, it is has been the best start up I have ever been involved in, in fact we haven't had any problems at all with the machine. This has a lot to do with how Saica management approached the project, there was a lot of planning that went into this start up, in fact, preparations were on an unprecedented scale," continues Hayrynen. "We had extensive training of our people in Spain and Finland before the start up, and it was absolutely crucial that this machine was the most automated as possible so that we could try to eliminate any ‘human factor' and minimize the amount of operator intervention. This was especially critical as more than 90% of our operators did not have any previous paper making experience.

"This approach has really worked," adds Hayrynen.

Saica sent Hayrynen and his team to Metso Automation's headquarters in Tampere, Finland, to take part in the Factory Acceptance Test (FAT) for the automation system to make sure that every eventuality of running a brand new paper machine was taken into consideration. Hayrynen says: "We left absolutely nothing to chance when it came to installing and starting up this machine at Partington, and Saica management planned everything meticulously. Basically what we have with PM 11 automation is push button technology from the stock prep to the winder and everything in between, we tested all of the sequences and phases during the FAT test in Tampere over three months, so that when we got onto the machine, there were no surprises."

Hayrynen estimates that PM 11 is 95% automated which is extremely impressive when you consider the phases a paper machine has to go through to get quality paper on the reel. For instance grade changes are 100% automated, and all done at the push of a button. "The speed and quality of the grade changes is spot on, and we can do a 20 g/m² grade change in seven minutes without any hands on intervention from the operators at all," adds Hayrynen.

Measuring enables managing

So what part of the automation system has helped most to achieve this ‘no surprises' production philosophy at Partington? Hayrynen highlights a number of Metso Automation solutions that particularly stand out as being instrumental in allowing the smooth running of PM 11: "The Metso DNA system is extremely operator friendly," he says. "All of the information I need is right there at my fingertips, making the whole operation of PM 11 transparent. Using the Operator Tracking System I can see exactly when grade changes have been made, where there were delays, analysis of alarms, and when manual mode has occurred.

"I can come in first thing in the morning and at the touch of a button see what happened on the night shift the night before, and not only where things went wrong, but where things went right, where we can learn about the phases of the machine when it is at its most productive," continues Hayrynen. "We use the operating tracking system a lot, it is a very powerful management tool."

Another favourite piece of the automation system on PM 11 is the Functional Description element, also on Metso DNA. Hayrynen explains: "Because our philosophy here of aiming for total automation, it means that the skills of our workforce can be honed in on getting the maximum production rates out of the machine, rather than the intricacies of paper making. The Functional Description mode on the Metso DNA system means that as soon as there is any kind of problem, the operator can zoom in on the area of concern, and automatically a screen will pop up telling him what should be happening, behind all the control loops, as well as the reason for the problem and where to go to fix it. This takes away all the time taken to search for the problem, isolate it, then wait for it to be fixed.

"This puts a microscope on the problem at the same time as coming up with a solution meaning we achieve maximum up-time," adds Hayrynen.

Up-time are key words at Saica right across the company, with the goal being at 90% plus across all units and facilities - and a very healthy competition exists within the company. Partington is well on the way to achieving this goal with Hayrynen stating that over the last three months PM 11 has hit the 90% up-time target consistently. Again, Metso Automation concepts come in here which have been designed to maximize up-time by remote monitoring. This is where engineers in Tampere use Metso's Process Performance Monitoring system to remotely analyse data from PM 11 making sure the machine is running in a completely stable environment. Hayrynen explains: "This is another powerful tool which allows the monitoring and managing of machine performance, making sure that there are minimum variations in moisture right the way across from stock approach through to the winder. It allows the engineers to isolate any areas of the machine that are underperforming, for instance valves, and then retune as and when necessary for maximum performance.

"We have regular meetings with the Metso team in Tampere, and they visit us here at the mill twice a year here when they tune the loops and valves and improve all the systems, which is part of our ongoing service contract," adds Hayrynen.

The challenges keep on coming...

Saica's Partington mill is a fantastic example of a modern mill, located in a busy metropolitan area, creating an environmentally friendly product to a bar-setting industry standard in terms of speed and quality. But there are limitations here when it comes to space, which means that the pressure is very much on for the mill to absolutely maximize its performance in every way to hit the targets and stay out in front. Hayrynen says: "We have our work cut out here, and as at any mill, when we solve one bottleneck another one automatically pops up. Our next project will probably be to increase the capacity in stock preparation, and improve consistency of raw material using Metso's microwave technology, but there are also other things on our wish list, for instance improving our steam network, and optimising it so that it programs automatically for the most efficient usage.

"One thing is for sure," concludes Hayrynen. "We will continue on the road of maximising efficiency and quality and keeping our costs down well into the future."

Pulp & Paper International is FREE to qualified subscribers.Click here to find out more.

"To achieve the quality that the market demands, and at the speed we demand, we need to take out all the inconsistency which often occurs because of the human element on the paper machine," says Pasi Hayrynen.

SAICA boosts capability with Metso Automation

07/07/2014 - 09:11

BRUSSELS, July 1, 2014 (PPI Magazine) - Just one step inside the machine hall at Saica's virtually brand new EUR 360 million containerboard mill at Partington, near the city of Manchester in the UK, reveals to the visitor that this mill is run with precision and pride. Minute attention to detail is simply part of everyday life here. Even the floor shines, and PM 11, the gleaming centrepiece of the whole operation, is possibly one of the quietest paper machines in the business - as well as being one of the most automated.

The mill itself was officially opened just a year ago, and is known in the industry as one of the most advanced, producing some 425,000 tonnes/yr of fluting and linerboard. At full capacity PM 11, which has a width at the reel of 7.7 m, will run at 1,500 m/min producing a weight range from 75 - 135 g/m² and the start up speed was a world record for these grades at 1,100 m/min.

In charge of the whole operation at the Partington site is Pasi Hayrynen, a seasoned Finnish papermaker with vast experience of some of the most challenging start-ups in Europe in recent times - particularly of those machines using 100% recovered paper. Hayrynen's professional experience has taken him all around Europe to countries including Spain and Finland, but his particular experience in the last three years has been in the UK with Palm Paper in Kings Lynn and now at the showcase Saica containerboard mill at Partington.

"10 years ahead of other Automation"

As anybody in the business area of making quality paper from 100% recovered material knows, achieving speed and quality is more akin to an art than a pure skill, and it is a question of getting a lot of things right - all at the same time. And this is where automation comes in. "To achieve the quality that the market demands, and at the speed we demand, we need to take out all the inconsistency which often occurs because of the human element on the paper machine," says Hayrynen. "We like an operating world of ‘no surprises' at this mill".

As one of the pillars of this ‘no surprises' working atmosphere at the mill, Metso Automation supplied the complete automation package for the Partington mill, which has already been described by Saica management as "10 years ahead of other automation". Hayrynen says: "At other mills we tend to use independent suppliers for automation, but Saica Partington was different as we went for Metso (now Valmet) as a machine supplier, so it was decided to use Metso Automation. It works well in this case as the two companies are in close communication with each other and there are all sorts of warranties and guarantees in place."

So how have operations been since the start up, and has PM 11 lived up to expectations? "Like all start ups in my experience, there were one or two teething problems to begin with," says Hayrynen, ‘"however, these problems were outside of Metso's scope of delivery.

"As far as the PM 11 goes, it is has been the best start up I have ever been involved in, in fact we haven't had any problems at all with the machine. This has a lot to do with how Saica management approached the project, there was a lot of planning that went into this start up, in fact, preparations were on an unprecedented scale," continues Hayrynen. "We had extensive training of our people in Spain and Finland before the start up, and it was absolutely crucial that this machine was the most automated as possible so that we could try to eliminate any ‘human factor' and minimize the amount of operator intervention. This was especially critical as more than 90% of our operators did not have any previous paper making experience.

"This approach has really worked," adds Hayrynen.

Saica sent Hayrynen and his team to Metso Automation's headquarters in Tampere, Finland, to take part in the Factory Acceptance Test (FAT) for the automation system to make sure that every eventuality of running a brand new paper machine was taken into consideration. Hayrynen says: "We left absolutely nothing to chance when it came to installing and starting up this machine at Partington, and Saica management planned everything meticulously. Basically what we have with PM 11 automation is push button technology from the stock prep to the winder and everything in between, we tested all of the sequences and phases during the FAT test in Tampere over three months, so that when we got onto the machine, there were no surprises."

Hayrynen estimates that PM 11 is 95% automated which is extremely impressive when you consider the phases a paper machine has to go through to get quality paper on the reel. For instance grade changes are 100% automated, and all done at the push of a button. "The speed and quality of the grade changes is spot on, and we can do a 20 g/m² grade change in seven minutes without any hands on intervention from the operators at all," adds Hayrynen.

Measuring enables managing

So what part of the automation system has helped most to achieve this ‘no surprises' production philosophy at Partington? Hayrynen highlights a number of Metso Automation solutions that particularly stand out as being instrumental in allowing the smooth running of PM 11: "The Metso DNA system is extremely operator friendly," he says. "All of the information I need is right there at my fingertips, making the whole operation of PM 11 transparent. Using the Operator Tracking System I can see exactly when grade changes have been made, where there were delays, analysis of alarms, and when manual mode has occurred.

"I can come in first thing in the morning and at the touch of a button see what happened on the night shift the night before, and not only where things went wrong, but where things went right, where we can learn about the phases of the machine when it is at its most productive," continues Hayrynen. "We use the operating tracking system a lot, it is a very powerful management tool."

Another favourite piece of the automation system on PM 11 is the Functional Description element, also on Metso DNA. Hayrynen explains: "Because our philosophy here of aiming for total automation, it means that the skills of our workforce can be honed in on getting the maximum production rates out of the machine, rather than the intricacies of paper making. The Functional Description mode on the Metso DNA system means that as soon as there is any kind of problem, the operator can zoom in on the area of concern, and automatically a screen will pop up telling him what should be happening, behind all the control loops, as well as the reason for the problem and where to go to fix it. This takes away all the time taken to search for the problem, isolate it, then wait for it to be fixed.

"This puts a microscope on the problem at the same time as coming up with a solution meaning we achieve maximum up-time," adds Hayrynen.

Up-time are key words at Saica right across the company, with the goal being at 90% plus across all units and facilities - and a very healthy competition exists within the company. Partington is well on the way to achieving this goal with Hayrynen stating that over the last three months PM 11 has hit the 90% up-time target consistently. Again, Metso Automation concepts come in here which have been designed to maximize up-time by remote monitoring. This is where engineers in Tampere use Metso's Process Performance Monitoring system to remotely analyse data from PM 11 making sure the machine is running in a completely stable environment. Hayrynen explains: "This is another powerful tool which allows the monitoring and managing of machine performance, making sure that there are minimum variations in moisture right the way across from stock approach through to the winder. It allows the engineers to isolate any areas of the machine that are underperforming, for instance valves, and then retune as and when necessary for maximum performance.

"We have regular meetings with the Metso team in Tampere, and they visit us here at the mill twice a year here when they tune the loops and valves and improve all the systems, which is part of our ongoing service contract," adds Hayrynen.

The challenges keep on coming...

Saica's Partington mill is a fantastic example of a modern mill, located in a busy metropolitan area, creating an environmentally friendly product to a bar-setting industry standard in terms of speed and quality. But there are limitations here when it comes to space, which means that the pressure is very much on for the mill to absolutely maximize its performance in every way to hit the targets and stay out in front. Hayrynen says: "We have our work cut out here, and as at any mill, when we solve one bottleneck another one automatically pops up. Our next project will probably be to increase the capacity in stock preparation, and improve consistency of raw material using Metso's microwave technology, but there are also other things on our wish list, for instance improving our steam network, and optimising it so that it programs automatically for the most efficient usage.

"One thing is for sure," concludes Hayrynen. "We will continue on the road of maximising efficiency and quality and keeping our costs down well into the future."

Pulp & Paper International is FREE to qualified subscribers.Click here to find out more.

ZARAGOZA, Spain, March 11, 2014 (Press Release) - SAICA has announced the acquisition of OMK the Turkish manufacturer of corrugated cardboard as part of its strategy to increase the footprint of the group in the East of Europe, to better support key customers as well as locally based businesses.

Access to reliable, high quality packaging design and print will be a key requirement for SAICA's customers to capitalise on the rapidly growing consumer market in Turkey, where GDP is forecast to grow at 4.5 % between 2014 and 2020.

OMK based in Eskisehir, North West Turkey, employs 260 people in the manufacture of corrugated cardboard and has sales of approximately 20 million euros.

SAICA believes that that the corrugated market in Turkey will grow strongly and has the potential to be one of the largest in Europe, driven by the demographics of the country and the robust record of economic growth.

"This is an important acquisition for SAICA as it not only gives us a strong position in a rapidly developing market but also enables us to better serve our key customers throughout their European operations," said Ramón Alejandro, President of SAICA.

"OMK is an excellent company and we have much to learn from each other as we look to integrate our operations and push forward for continuous improvement and innovation. In recent years we have made a number of significant acquisitions across Europe and therefore we know how to get the best from those companies we acquire effectively and efficiently. Key to this is recognising that both sides have much to contribute and therefore building a combined culture that enables this to happen is very important and will be a key focus of our early work together," continued Mr Alejandro.

As a privately owned company SAICA invests for the long term and the broader strategy is to build an integrated sustainable model involving recycled containerboard making, corrugated manufacture, recovering of paper for recycling and environmental services in much the same way as has been so successful in other European markets, where the template is now well established.

This is the second significant acquisition SAICA has made in 2014 following the announcement in February that Spanish manufacturer Microlan is to become part of the group.

SAICA boosts its presence in Turkey

03/17/2014 - 12:28

ZARAGOZA, Spain, March 11, 2014 (Press Release) - SAICA has announced the acquisition of OMK the Turkish manufacturer of corrugated cardboard as part of its strategy to increase the footprint of the group in the East of Europe, to better support key customers as well as locally based businesses.

Access to reliable, high quality packaging design and print will be a key requirement for SAICA's customers to capitalise on the rapidly growing consumer market in Turkey, where GDP is forecast to grow at 4.5 % between 2014 and 2020.

OMK based in Eskisehir, North West Turkey, employs 260 people in the manufacture of corrugated cardboard and has sales of approximately 20 million euros.

SAICA believes that that the corrugated market in Turkey will grow strongly and has the potential to be one of the largest in Europe, driven by the demographics of the country and the robust record of economic growth.

"This is an important acquisition for SAICA as it not only gives us a strong position in a rapidly developing market but also enables us to better serve our key customers throughout their European operations," said Ramón Alejandro, President of SAICA.

"OMK is an excellent company and we have much to learn from each other as we look to integrate our operations and push forward for continuous improvement and innovation. In recent years we have made a number of significant acquisitions across Europe and therefore we know how to get the best from those companies we acquire effectively and efficiently. Key to this is recognising that both sides have much to contribute and therefore building a combined culture that enables this to happen is very important and will be a key focus of our early work together," continued Mr Alejandro.

As a privately owned company SAICA invests for the long term and the broader strategy is to build an integrated sustainable model involving recycled containerboard making, corrugated manufacture, recovering of paper for recycling and environmental services in much the same way as has been so successful in other European markets, where the template is now well established.

This is the second significant acquisition SAICA has made in 2014 following the announcement in February that Spanish manufacturer Microlan is to become part of the group.

The new acquisition consolidates SAICA's leadership in the Spanish and Portuguese markets.
The Spanish Multinational continues promoting sustainable packaging solutions.

ZARAGOZA, Spain, Feb. 27, 2014 (Press Release) - Saica, a company that develops and produces sustainable solutions for recycled corrugating packaging, corrugated board and environmental services, has acquired the company Microlan for its Pack Division in Alcobendas, Madrid. Microlan belongs to the Lantero Machieraldo family. With a workforce of 120 people and an annual turnover of 25,8 million €, this represents a step ahead in Saica Iberia's growth strategy.

Through this acquisition, Saica strengthens and completes its presence in the Spanish and Portuguese high-performance corrugated board market. The incorporation of Microlan reinforces the multinational's aim to development the niche for high-quality design and printed packaging in the high added value sectors, which play a decisive role in the sale of the products.

Saica thus consolidates its leadership in the corrugated packaging market and maintains its strategic commitment to the promotion of sustainable solutions based on high-performance lightweight papers, the innovation of new flutes and paper compositions, all characterized by high quality design and printing.

"High quality printing on packaging is becoming a basic ally to our customers when presenting their products to their end-consumers. In Saica we keep on furthering our engagement towards our customers and the incorporation of Microlan allows us to complete our range of products in the Iberian market, not only by means of its state-of-the-art printing technology, but also through its knowledge, experience and team", explained Ramón Alejandro, Saica President.

Saica acquires Microlan for its pack division in Alcobendas, Madrid

03/03/2014 - 01:50

The new acquisition consolidates SAICA's leadership in the Spanish and Portuguese markets.
The Spanish Multinational continues promoting sustainable packaging solutions.

ZARAGOZA, Spain, Feb. 27, 2014 (Press Release) - Saica, a company that develops and produces sustainable solutions for recycled corrugating packaging, corrugated board and environmental services, has acquired the company Microlan for its Pack Division in Alcobendas, Madrid. Microlan belongs to the Lantero Machieraldo family. With a workforce of 120 people and an annual turnover of 25,8 million €, this represents a step ahead in Saica Iberia's growth strategy.

Through this acquisition, Saica strengthens and completes its presence in the Spanish and Portuguese high-performance corrugated board market. The incorporation of Microlan reinforces the multinational's aim to development the niche for high-quality design and printed packaging in the high added value sectors, which play a decisive role in the sale of the products.

Saica thus consolidates its leadership in the corrugated packaging market and maintains its strategic commitment to the promotion of sustainable solutions based on high-performance lightweight papers, the innovation of new flutes and paper compositions, all characterized by high quality design and printing.

"High quality printing on packaging is becoming a basic ally to our customers when presenting their products to their end-consumers. In Saica we keep on furthering our engagement towards our customers and the incorporation of Microlan allows us to complete our range of products in the Iberian market, not only by means of its state-of-the-art printing technology, but also through its knowledge, experience and team", explained Ramón Alejandro, Saica President.

HEIDENHEIM, Germany, Feb. 5, 2014 (Press Release) - When building its new mill in Partington, Great Britain, the paper manufacturer Saica chose Voith's wastewater treatment system with an R2S reactor, which is a two-stage high-performance reactor for anaerobic treatment of industrial wastewater. Voith has already sold 19 of these reactor types worldwide.

Saica is very satisfied with its new system. Federico Asensio, the Deputy General Manager and RD Group Director at Saica, is happy to confirm this: "For a customer, it is important to rely on the technical know-how and commitment of the supplier, especially if there is an unexpected situation. Thanks to the strong collaboration between Voith and Saica, the initial problems have been solved and the wastewater treatment system finally achieved our original expectations. Its operation is smooth and stable."

At Saica, wastewater treatment is coordinated very precisely to the specifics of paper manufacturing. The system is designed for daily production amounting to 1,400 metric tons of corrugated board base paper from 100% recovered paper, and thus for ca. 6,300 m³ of wastewater daily.

The rugged R2S reactor at Saica breaks down around 80% of the load. Up to 25,000 Nm³ of biogas is produced daily. This gas is available as an additional energy source and can be used for steam or power generation. As the concept is specifically coordinated to the paper mill, the limit values for the wastewater are also reliably and safely adhered to. The amount of excess sludge is also reduced.

Saica chooses Voith’s R2S reactor for wastewater treatment

Posted in: Bio-Insight 02/05/2014 - 07:46

HEIDENHEIM, Germany, Feb. 5, 2014 (Press Release) - When building its new mill in Partington, Great Britain, the paper manufacturer Saica chose Voith's wastewater treatment system with an R2S reactor, which is a two-stage high-performance reactor for anaerobic treatment of industrial wastewater. Voith has already sold 19 of these reactor types worldwide.

Saica is very satisfied with its new system. Federico Asensio, the Deputy General Manager and RD Group Director at Saica, is happy to confirm this: "For a customer, it is important to rely on the technical know-how and commitment of the supplier, especially if there is an unexpected situation. Thanks to the strong collaboration between Voith and Saica, the initial problems have been solved and the wastewater treatment system finally achieved our original expectations. Its operation is smooth and stable."

At Saica, wastewater treatment is coordinated very precisely to the specifics of paper manufacturing. The system is designed for daily production amounting to 1,400 metric tons of corrugated board base paper from 100% recovered paper, and thus for ca. 6,300 m³ of wastewater daily.

The rugged R2S reactor at Saica breaks down around 80% of the load. Up to 25,000 Nm³ of biogas is produced daily. This gas is available as an additional energy source and can be used for steam or power generation. As the concept is specifically coordinated to the paper mill, the limit values for the wastewater are also reliably and safely adhered to. The amount of excess sludge is also reduced.

BRUSSELS, May 20, 2013 (RISI) - The UK's Manchester Ship Canal officially opened in January 1894 after a seven year construction period. It is an engineering feat of monumental proportions and is clearly one of the greatest technological achievements of the Victorian age. The canal connects the City of Manchester to the open sea, a distance of 40 miles. It is still the longest river navigation canal in the world and remains the world's eighth-longest ship canal, only slightly shorter than the Panama Canal in Central America. Its introduction was a major factor in Manchester and the surrounding Lancashire towns becoming major centres of trade over the following century.

Turn the clock forwards 110 years and, yet again, great technological strides are taking place alongside the Manchester Ship Canal. On April 24, SAICA's new recycled paper mill was officially opened by the UK's Business and Energy minister Michael Fallon. Alongside many local and regional dignitaries the event was also attended by the British Ambassador to Spain, Giles Paxman and president of SAICA Ramon Alejandro. The new £300 million PM 11 containerboard mill is situated alongside the Manchester Ship Canal in Partington, a small town just to the west of Manchester. Papermaking is a long-established tradition in Partington as paper has been made in the town since 1756. The new SAICA mill will produce 450,000 tonnes of recycled containerboard each year from 100% recovered fiber. The mill began to produce commercial quality containerboard last year and all systems have been tested and production increased since that time. The cost of the new mill forms part of a £500 million ($750 million) investment by SAICA in the UK. The mill is now operating at full capacity and can produce around 8,000 tonnes of material per week in substances from 75 - 135 g/m².

PM 11's sustainability claims are impressive. The company's core activity, the manufacturing of recycled paper for corrugated packaging, is essentially sustainable as it only uses recovered paper as its main raw material. The site is FSC and PEFC accredited. The new machine produces world-leading, low basis weight performance papers used in corrugated packaging - minimizing the amount of water and electricity consumption per tonne of paper produced. It employs state-of-the-art technologies to minimize the environmental impact of producing containerboard papers and is designed to use 40% less water and 50% less electricity per tonne of paper than the industry's reference points (BREF and BAT). When fully operational, PM 11, supplied by Metso (see PPI May 2012), will reduce carbon emissions by 84,011 tonnes/yr - the equivalent of taking 28,000 cars off the road each year. This figure is based on The Carbon Trust's published CO2 emission figures for the average petrol car in the UK driving the UK-average 14,500 km per year. With the UK currently exporting a total of 4,000,000 tonnes of recovered paper to Asia (mainly China) every year and releasing between 154 and 213 kg of of CO2 for each tonne transported, any opportunity to recycle UK-based recovered paper in the country is welcome. The Partington operation recycles around 450,000 tonnes of used paper to produce 400,000 tonnes/yr of lightweight performance paper for use in corrugated packaging - reducing the amount of recovered paper sent to China by 11.25%.

Reducing PM 11's energy consumption is very important for SAICA. Not only does it provide a reduction in the cost base, but it also reduces the environmental impacts of making the paper, improving SAICA's sustainability and reducing their customers' carbon footprints. The combined heat and power (CHP) plant at PM 11 uses biogas produced on site to provide its steam and electricity requirements and also generates a surplus of electricity, which is exported to the national grid. The use of CHP at PM 11 saves approximately 7,300 tonnes of CO2 emissions each year.

In addition to the CHP plant, PM 11 also has a small energy recovery boiler to further reduce the environmental impact of the paper mill and avoid the need to send these residual materials for land spreading or environmentally unsustainable landfill sites, with associated transport implications. The energy recovery boiler is a small but important part of the overall process and ensures that SAICA maximizes the use of all the raw material, minimizes its energy needs and minimizes the disposal of residues to landfill. The amount of material left for traditional disposal is significantly reduced.

In total the energy efficiency for PM 11 will be nearly 80% - compared with a traditional power station's energy efficiency of only 30%. These high levels of efficiency reduce PM 11's carbon emissions and avoid the import of comparatively inefficiently produced power from the national grid.

PM 11 generates around 33-37 MW of electricity and 75-90 tonnes of steam per hour. Around 21-24 MW of electricity and 75-90 tonnes/hr of steam are required for the mill's operation. The balance of the electricity generated (enough to power around 20,000 homes) will be delivered to the national grid.

PM 11 is also designed to be as water efficient as possible. The water drawn from the Manchester Ship Canal is thoroughly cleaned and returned to it, in accordance with strict conditions set by the UK's Environment Agency.

At the opening ceremony Business and Energy minister Fallon said, "This cutting edge facility shows how state of the art technology and innovation can help drive growth. It is a real boost for the economy and will create new jobs for Partington and the local area. We are becoming an increasingly green economy and starting to reduce the impact of industry on the environment. So it's promising to see the new facility will prevent thousands of tonnes of carbon from entering the atmosphere."

SAICA president Ramon Alejandro commented, ‘We are thrilled that our world-leading facility is now running at full capacity and are proud to officially open PM 11. Our customers deserve the best and we have been determined to deliver a facility that produces high quality performance papers. This is a significant investment for SAICA and demonstrates our commitment to both our UK customers and the wider economy."

At an interview later in the day PPI asked Alejandro about SAICA's plans for Central and Eastern Europe (CEE), given its recent acquisition of Polish packaging firm T.O.P. in conjunction with Thimm Verpackung. Alejandro said, ‘We have a 49% stake in that business. We are approaching the CEE as we approach any other area of our business operations. We will invest in the businesses that we own and develop their productivity. For instance, in Poland we have commissioned a new building and purchased new corrugating equipment at the plant. We are now considering the possibility of a future investment in finishing equipment for that operation. If other opportunities arise, within CEE or elsewhere, we will consider them and act in SAICA's best interests.'

Asked about the impact that SAICA will have on the UK corrugated industry and the changes that he envisaged for the industry in the future Alejandro explained, ‘The UK corrugated industry has already undergone considerable consolidation. In mainland Europe more consolidation can be anticipated in the future. In my view SAICA does not need to be the biggest player in the market. That is not our intention. We are striving to provide service; quality; sustainability and profitability. Those are our aims. We are operating in the UK because we see a place for us in this market and our results are already proving that we have made the right decision to be here. The UK will rapidly become one of our biggest markets. This gives us additional benefits as we are totally reliant on the Iberian market.' He went on to explain that PM 11 produces corrugated and fluting. Of the total production, 65% is earmarked for conversion within the SAICA group; 10% will be exported (mainly to northern France and Germany) and the balance will be sold in the UK and Ireland.'

He continued, "We are still a family business and there are many advantages to this. It is much easier for us to make long-term plans than be forced into short-term decisions. In addition we can act quickly and decisively if required. For example, we received planning permission for PM 11 back in 2008. When the economic downturn came we decided to put the project on hold. The decision to proceed when markets improved in 2010 was taken promptly too. We may not have been able to react so quickly if we had not got family control of the business."

In closing it would be appropriate to make a comparison of technological development on the Partington site. PM 11 draws its water from the adjacent Manchester Ship Canal. This neatly connects the pinnacle of 19th century industrial development with 21st century recovered fiber innovation. SAICA approaches the future with confidence.

SAICA UK mill receives official inauguration

05/20/2013 - 05:56

BRUSSELS, May 20, 2013 (RISI) - The UK's Manchester Ship Canal officially opened in January 1894 after a seven year construction period. It is an engineering feat of monumental proportions and is clearly one of the greatest technological achievements of the Victorian age. The canal connects the City of Manchester to the open sea, a distance of 40 miles. It is still the longest river navigation canal in the world and remains the world's eighth-longest ship canal, only slightly shorter than the Panama Canal in Central America. Its introduction was a major factor in Manchester and the surrounding Lancashire towns becoming major centres of trade over the following century.

Turn the clock forwards 110 years and, yet again, great technological strides are taking place alongside the Manchester Ship Canal. On April 24, SAICA's new recycled paper mill was officially opened by the UK's Business and Energy minister Michael Fallon. Alongside many local and regional dignitaries the event was also attended by the British Ambassador to Spain, Giles Paxman and president of SAICA Ramon Alejandro. The new £300 million PM 11 containerboard mill is situated alongside the Manchester Ship Canal in Partington, a small town just to the west of Manchester. Papermaking is a long-established tradition in Partington as paper has been made in the town since 1756. The new SAICA mill will produce 450,000 tonnes of recycled containerboard each year from 100% recovered fiber. The mill began to produce commercial quality containerboard last year and all systems have been tested and production increased since that time. The cost of the new mill forms part of a £500 million ($750 million) investment by SAICA in the UK. The mill is now operating at full capacity and can produce around 8,000 tonnes of material per week in substances from 75 - 135 g/m².

PM 11's sustainability claims are impressive. The company's core activity, the manufacturing of recycled paper for corrugated packaging, is essentially sustainable as it only uses recovered paper as its main raw material. The site is FSC and PEFC accredited. The new machine produces world-leading, low basis weight performance papers used in corrugated packaging - minimizing the amount of water and electricity consumption per tonne of paper produced. It employs state-of-the-art technologies to minimize the environmental impact of producing containerboard papers and is designed to use 40% less water and 50% less electricity per tonne of paper than the industry's reference points (BREF and BAT). When fully operational, PM 11, supplied by Metso (see PPI May 2012), will reduce carbon emissions by 84,011 tonnes/yr - the equivalent of taking 28,000 cars off the road each year. This figure is based on The Carbon Trust's published CO2 emission figures for the average petrol car in the UK driving the UK-average 14,500 km per year. With the UK currently exporting a total of 4,000,000 tonnes of recovered paper to Asia (mainly China) every year and releasing between 154 and 213 kg of of CO2 for each tonne transported, any opportunity to recycle UK-based recovered paper in the country is welcome. The Partington operation recycles around 450,000 tonnes of used paper to produce 400,000 tonnes/yr of lightweight performance paper for use in corrugated packaging - reducing the amount of recovered paper sent to China by 11.25%.

Reducing PM 11's energy consumption is very important for SAICA. Not only does it provide a reduction in the cost base, but it also reduces the environmental impacts of making the paper, improving SAICA's sustainability and reducing their customers' carbon footprints. The combined heat and power (CHP) plant at PM 11 uses biogas produced on site to provide its steam and electricity requirements and also generates a surplus of electricity, which is exported to the national grid. The use of CHP at PM 11 saves approximately 7,300 tonnes of CO2 emissions each year.

In addition to the CHP plant, PM 11 also has a small energy recovery boiler to further reduce the environmental impact of the paper mill and avoid the need to send these residual materials for land spreading or environmentally unsustainable landfill sites, with associated transport implications. The energy recovery boiler is a small but important part of the overall process and ensures that SAICA maximizes the use of all the raw material, minimizes its energy needs and minimizes the disposal of residues to landfill. The amount of material left for traditional disposal is significantly reduced.

In total the energy efficiency for PM 11 will be nearly 80% - compared with a traditional power station's energy efficiency of only 30%. These high levels of efficiency reduce PM 11's carbon emissions and avoid the import of comparatively inefficiently produced power from the national grid.

PM 11 generates around 33-37 MW of electricity and 75-90 tonnes of steam per hour. Around 21-24 MW of electricity and 75-90 tonnes/hr of steam are required for the mill's operation. The balance of the electricity generated (enough to power around 20,000 homes) will be delivered to the national grid.

PM 11 is also designed to be as water efficient as possible. The water drawn from the Manchester Ship Canal is thoroughly cleaned and returned to it, in accordance with strict conditions set by the UK's Environment Agency.

At the opening ceremony Business and Energy minister Fallon said, "This cutting edge facility shows how state of the art technology and innovation can help drive growth. It is a real boost for the economy and will create new jobs for Partington and the local area. We are becoming an increasingly green economy and starting to reduce the impact of industry on the environment. So it's promising to see the new facility will prevent thousands of tonnes of carbon from entering the atmosphere."

SAICA president Ramon Alejandro commented, ‘We are thrilled that our world-leading facility is now running at full capacity and are proud to officially open PM 11. Our customers deserve the best and we have been determined to deliver a facility that produces high quality performance papers. This is a significant investment for SAICA and demonstrates our commitment to both our UK customers and the wider economy."

At an interview later in the day PPI asked Alejandro about SAICA's plans for Central and Eastern Europe (CEE), given its recent acquisition of Polish packaging firm T.O.P. in conjunction with Thimm Verpackung. Alejandro said, ‘We have a 49% stake in that business. We are approaching the CEE as we approach any other area of our business operations. We will invest in the businesses that we own and develop their productivity. For instance, in Poland we have commissioned a new building and purchased new corrugating equipment at the plant. We are now considering the possibility of a future investment in finishing equipment for that operation. If other opportunities arise, within CEE or elsewhere, we will consider them and act in SAICA's best interests.'

Asked about the impact that SAICA will have on the UK corrugated industry and the changes that he envisaged for the industry in the future Alejandro explained, ‘The UK corrugated industry has already undergone considerable consolidation. In mainland Europe more consolidation can be anticipated in the future. In my view SAICA does not need to be the biggest player in the market. That is not our intention. We are striving to provide service; quality; sustainability and profitability. Those are our aims. We are operating in the UK because we see a place for us in this market and our results are already proving that we have made the right decision to be here. The UK will rapidly become one of our biggest markets. This gives us additional benefits as we are totally reliant on the Iberian market.' He went on to explain that PM 11 produces corrugated and fluting. Of the total production, 65% is earmarked for conversion within the SAICA group; 10% will be exported (mainly to northern France and Germany) and the balance will be sold in the UK and Ireland.'

He continued, "We are still a family business and there are many advantages to this. It is much easier for us to make long-term plans than be forced into short-term decisions. In addition we can act quickly and decisively if required. For example, we received planning permission for PM 11 back in 2008. When the economic downturn came we decided to put the project on hold. The decision to proceed when markets improved in 2010 was taken promptly too. We may not have been able to react so quickly if we had not got family control of the business."

In closing it would be appropriate to make a comparison of technological development on the Partington site. PM 11 draws its water from the adjacent Manchester Ship Canal. This neatly connects the pinnacle of 19th century industrial development with 21st century recovered fiber innovation. SAICA approaches the future with confidence.

ZARAGOZA, Spain, April 24, 2013 (Press Release) -Europe's most advanced recycled paper mill was officially opened today by Rt Hon Michael Fallon MP, Minister of State for Business & Energy. The £300 million facility, known as PM-11, was built by Spanish multinational paper and corrugated packaging manufacturer SAICA at Partington Wharfside, Trafford.

PM-11 is SAICA's first recycled paper mill in the UK and the first ‘new' containerboard paper mill to be built in the UK for decades. It will produce 450,000tpa of 100% recycled containerboard each year from UK recovered papers.

The facility is the final part of SAICA's £0.5 billion investment plan to become an integrated player in the UK's packaging sector, providing a closed-loop solution for the manufacture of environmentally friendly, performance papers and corrugated packaging. PM-11 has led to the creation of 94 direct jobs plus opportunities for contractors and other roles.

PM-11 successfully produced paper for the first time on Sunday 15th January 2012 - two weeks ahead of the project start date and setting a new world start up speed record at 1.105 m/min 95 gr/m2.

Since that time, the company has been taking the facility through the commissioning phase, testing all parts of the paper machine and ancillary equipment; and steadily increasing production.

PM-11 is now operating at full capacity, producing 1,500 metres per minute of performance papers in the 75-135gsm range - enough to cover the 196 mile distance between Partington and London every three hours.

The new paper mill will help to divert the export of some 450,000 tonnes a year of used paper by recycling it within the UK - reducing carbon emissions by 84,011 tonnes per year - the equivalent of taking 28,000 cars off the road each year.

Business and Energy Minister Michael Fallon said:

"This cutting edge facility shows how state of the art technology and innovation can help drive growth. It's a real boost for the economy and will create new jobs for Partington and the local area.

"We are becoming an increasingly green economy and starting to reduce the impact of industry on the environment. So it's promising to see the new facility will prevent thousands of tonnes of carbon from entering the atmosphere."

Speaking ahead of PM-11's inauguration, SAICA President Ramón Alejandro said:

"We are thrilled that our world-leading facility is now running at full capacity and are proud to officially open PM-11 that has already set new records.

"Our customers deserve the best and we have been determined to deliver a facility that produces high quality performance papers.

"This is a significant investment for SAICA and demonstrates our commitment to both our UK customers and boosting the wider economy.

"We are delighted that the UK's Minister of State for Business & Enterprise has recognised this important milestone and the level of investment it has taken to reach this stage."

SAICA officially opens £300 million PM-11 recycled containerboard facility at Partington Wharfside in the UK

Posted in: Packaging Technology 04/24/2013 - 21:32

ZARAGOZA, Spain, April 24, 2013 (Press Release) -Europe's most advanced recycled paper mill was officially opened today by Rt Hon Michael Fallon MP, Minister of State for Business & Energy. The £300 million facility, known as PM-11, was built by Spanish multinational paper and corrugated packaging manufacturer SAICA at Partington Wharfside, Trafford.

PM-11 is SAICA's first recycled paper mill in the UK and the first ‘new' containerboard paper mill to be built in the UK for decades. It will produce 450,000tpa of 100% recycled containerboard each year from UK recovered papers.

The facility is the final part of SAICA's £0.5 billion investment plan to become an integrated player in the UK's packaging sector, providing a closed-loop solution for the manufacture of environmentally friendly, performance papers and corrugated packaging. PM-11 has led to the creation of 94 direct jobs plus opportunities for contractors and other roles.

PM-11 successfully produced paper for the first time on Sunday 15th January 2012 - two weeks ahead of the project start date and setting a new world start up speed record at 1.105 m/min 95 gr/m2.

Since that time, the company has been taking the facility through the commissioning phase, testing all parts of the paper machine and ancillary equipment; and steadily increasing production.

PM-11 is now operating at full capacity, producing 1,500 metres per minute of performance papers in the 75-135gsm range - enough to cover the 196 mile distance between Partington and London every three hours.

The new paper mill will help to divert the export of some 450,000 tonnes a year of used paper by recycling it within the UK - reducing carbon emissions by 84,011 tonnes per year - the equivalent of taking 28,000 cars off the road each year.

Business and Energy Minister Michael Fallon said:

"This cutting edge facility shows how state of the art technology and innovation can help drive growth. It's a real boost for the economy and will create new jobs for Partington and the local area.

"We are becoming an increasingly green economy and starting to reduce the impact of industry on the environment. So it's promising to see the new facility will prevent thousands of tonnes of carbon from entering the atmosphere."

Speaking ahead of PM-11's inauguration, SAICA President Ramón Alejandro said:

"We are thrilled that our world-leading facility is now running at full capacity and are proud to officially open PM-11 that has already set new records.

"Our customers deserve the best and we have been determined to deliver a facility that produces high quality performance papers.

"This is a significant investment for SAICA and demonstrates our commitment to both our UK customers and boosting the wider economy.

"We are delighted that the UK's Minister of State for Business & Enterprise has recognised this important milestone and the level of investment it has taken to reach this stage."

ZARAGOZA, Spain, March 1, 2011 (Press Release) -In only seven weeks, GE has completed a major "flange-to-flange" upgrade of a Frame 6B gas turbine at an industrial recycling paper mill in El Burgo de Ebro (Zaragoza), Spain. Replacing the key components of the gas turbine with new, advanced design parts has resulted in increased operating efficiency, a significant reduction in emissions and a considerable life extension for the plant. The project marked the world's first flange-to-flange replacement for a GE 6B gas turbine.

The paper mill is owned by S.A. Industrias Celulosa Aragonesa (SAICA), an international company that specializes in the production of corrugated cardboard boxes. The gas turbine upgrade will enable the SAICA plant to continue to receive the total feed-in tariff from the Spanish government. According to the Spanish legislation, cogeneration plants under 50 megawatts no longer qualify for the total feed-in tariff after 15 years of operation unless they adopt more efficient and environmentally responsible technologies as specified in the legislation.

"SAICA is fully committed to supplying sustainable quality products to the industry," said Antonio Pérez Palacio, energy and services director of SAICA Group. "The agreement with GE reinforces SAICA's position as a European leader both in efficiency and sustainability-key factors critical to the success in the global paper industry. GE's capacity to comply with the tight schedule was critical in order to restart operation of the plant as early as possible."

The upgraded Frame 6B at the SAICA cogeneration plant delivers approximately 38 megawatts of power, which is then sold to the national power grid, and produces steam for use in the paper production process. The project included the installation of GE's dry low NOx (DLN) combustion technology to reduce NOx emissions from around 150ppm to less than 15ppm without steam injection.

"Offering increased efficiency, higher performance and emissions control, this gas turbine upgrade program supports our commitment to deliver solutions that allow our customers to operate their plants in a cleaner, smarter and more efficient way," said Corinne de Bilbao, general manager of GE Energy Services, Western Europe and North West Africa. "The SAICA project is our first 6B flange-to-flange replacement project in the world and will serve as a model for future applications throughout the region. This type of upgrade brings significant results in a much shorter time than replacing the old gas turbine with a new unit would require."

GE completes upgrade of gas turbine at SAICA's recycled containerboard mill in El Burgo de Ebro, Spain

02/28/2011 - 17:44

ZARAGOZA, Spain, March 1, 2011 (Press Release) -In only seven weeks, GE has completed a major "flange-to-flange" upgrade of a Frame 6B gas turbine at an industrial recycling paper mill in El Burgo de Ebro (Zaragoza), Spain. Replacing the key components of the gas turbine with new, advanced design parts has resulted in increased operating efficiency, a significant reduction in emissions and a considerable life extension for the plant. The project marked the world's first flange-to-flange replacement for a GE 6B gas turbine.

The paper mill is owned by S.A. Industrias Celulosa Aragonesa (SAICA), an international company that specializes in the production of corrugated cardboard boxes. The gas turbine upgrade will enable the SAICA plant to continue to receive the total feed-in tariff from the Spanish government. According to the Spanish legislation, cogeneration plants under 50 megawatts no longer qualify for the total feed-in tariff after 15 years of operation unless they adopt more efficient and environmentally responsible technologies as specified in the legislation.

"SAICA is fully committed to supplying sustainable quality products to the industry," said Antonio Pérez Palacio, energy and services director of SAICA Group. "The agreement with GE reinforces SAICA's position as a European leader both in efficiency and sustainability-key factors critical to the success in the global paper industry. GE's capacity to comply with the tight schedule was critical in order to restart operation of the plant as early as possible."

The upgraded Frame 6B at the SAICA cogeneration plant delivers approximately 38 megawatts of power, which is then sold to the national power grid, and produces steam for use in the paper production process. The project included the installation of GE's dry low NOx (DLN) combustion technology to reduce NOx emissions from around 150ppm to less than 15ppm without steam injection.

"Offering increased efficiency, higher performance and emissions control, this gas turbine upgrade program supports our commitment to deliver solutions that allow our customers to operate their plants in a cleaner, smarter and more efficient way," said Corinne de Bilbao, general manager of GE Energy Services, Western Europe and North West Africa. "The SAICA project is our first 6B flange-to-flange replacement project in the world and will serve as a model for future applications throughout the region. This type of upgrade brings significant results in a much shorter time than replacing the old gas turbine with a new unit would require."

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