Operations Producer

JOHANNESBURG, Sept. 7, 2020 (Press Release) -One of the key concerns of the packaging industry is the development of sustainable value chains and environmentally friendly packaging processes. With this in mind, the machine manufacturer Rovema and the speciality paper manufacturer Sappi, two international leaders when it comes to sustainability, have entered into a strategic partnership. The two companies now cap their previous development work with the first successfully completed project for a well-known cereal manufacturer that switched its fully automated production to paper-based, sealable barrier pouches.

• Paper-based barrier packaging solutions
• High precision in the interaction between material and machine
• Minimized loss of performance during material changeover

Sappi is a leading provider of sustainable wood fibre products and material solutions. Rovema was particularly impressed by Sappi’s expertise in packaging and speciality papers with integrated barrier properties and sealability. Like Sappi, the packaging machine manufacturer from Fernwald, Germany, strives for continuous development as a ‘sustainable company’ as part of its firmly established mission statement. In addition to its approach of optimizing existing machine technology, such as the service life of wear parts and general recycling management, Rovema pays special attention to the idea of transitioning packaging materials. This involves reducing the use of plastic film and moving towards paper-based solutions and recyclable plastic materials.

The exceptional quality of Sappi’s products, its consultation service, portfolio and the outstanding properties of its barrier papers shone through. The two companies have been in partnership since 2018 and have developed integrated packaging solutions as a complete package for customers that are looking to prepare for the future and establish a strong foothold in the market.

Paper-based packaging materials in the packaging process

‘There are not many paper manufacturers that can combine key properties such as barrier functions and sealability,’ says Peter Lökös, Vice President Sales at Rovema GmbH, in relation to the new cooperation between his company and Sappi. ‘It was clear to us from the very beginning that we would stand to benefit substantially from developing our customer projects in direct cooperation with Sappi. The considerable knowledge and experience of the speciality paper experts enabled us to take a big step forward.’ This is because, unlike in the case of pouches and flat bags made from composite materials, as the more sustainable, paper-based alternatives need to be handled with far more care during the production process. In automated packaging processes, for example, paper tolerates only a small amount of tension transfer and tears more easily. The perforation resistance of the paper used also needs to be taken into account much more during filling.

René Köhler, Head of New Business Development Packaging Solutions, Division Innovation & Sustainability at Sappi, understands how important it is to have a precise understanding and analysis of the application demand, in order to choose the right paper qualities. ‘There is no need to use a high-barrier paper such as Sappi Guard OHG if a lower version such as Sappi Guard Nature MS can offer the necessary protection and functionality. To achieve top-class results, detailed knowledge of the product requirements on the one hand and the specific properties of the different papers on the other hand is very important for ultimately making the choice of packaging material.’

Performance precision makes the difference

High precision in the overall movement sequence of the equipment is also required to ensure successful use of environmentally friendly packaging materials – something which is a unique selling point of Rovema. In contrast to its competitors, the machine manufacturer relies on completely servo motor-driven conveying and sealing technology. In addition, all steps from forming to sealing the pouches are perfectly synchronized down to the finest detail to minimize the stress on the packaging material.

Strong partners for customers

Thanks to this collective expertise and integrated cooperation of both partners, the typical performance losses of 30 per cent or more when switching to a paper-based packaging material were reduced to just 10 to 15 per cent in the pilot project. Two further application projects are already in the development stage. The two companies are also well positioned to successfully implement paper-based packaging solutions for future customer demands. The focus will be on implementation for high-throughput applications in the area of confectionery and snacks. The two partners will present the initial results soon.

About Rovema:

ROVEMA GmbH has been developing and building packaging machines and systems that meet the complex demands of the modern circular economy for over 60 years. ROVEMA adopts a holistic approach and takes the environment, market, product and packaging in projects into account from the very beginning. This enables the development of efficient, future-proof packaging machines with high availability. The top priority for ROVEMA is a sustainable solution that meets the needs of the product being packaged as well as the requirements in terms of logistics, packaging materials, shelf life and energy efficiency. A blueprint for success – ROVEMA has supplied more than 30,000 machines and systems worldwide and employs over 600 people. ROVEMA achieved a turnover of around €100 million in 2019.

GAVLE, Sweden , Aug. 28, 2020 (Press Release) -On August 19th the world unique automated high-bay warehouse for paper was inaugurated in the Port of Gävle. The ceremonial ribbon cutting was done by Sweden’s Minister for Foreign Trade and Minister for Nordic Affairs, Anna Hallberg.

This is an incredibly important investment and hub for Gävle, Sweden and the world to gain access to Swedish products. I'm incredibly proud to see this building. We will be a role model for modern logistics where we have thought sustainably, long-term and for growth, said Foreign Trade Minister Anna Hallberg.

Due to the pandemic the inauguration was limited to 50 people. Present at the inauguration were mostly existing or potential customers but also politicians and journalists.

The warehouse will be operational in September with the first trains coming beginning of October.

This will be a competitive and sustainable solution for us and our customers. We will start with paper from our Frövi mill and later we might route more volumes here, step by step said Peter Olson, Logistics Director, BillerudKorsnäs.

Paper industry is core to the Swedish economy and growing. New infrastructure for smarter logistics is needed.

Paper is the most important commodity in our region and we believe it has a huge potential for the port. This investment is our contribution and we are confident it will be successful said Eryn Dinyovszky, General Manager of Yilport Nordic.

The CFS Paper investment is part of a larger investment plan that will see a brand-new container terminal with increased depth, three new STS cranes and six new RTG’s.

We have a great cooperation with the port authority and the municipality in Gävle. YILPORT is a game changer and we invest in the future said Mr Robert Yüksel Yildrim, CEO and owner of YILPORT.

During the ceremony, participants could see the cranes and conveyor belts working and send rolls in and out of the warehouse. Paper rolls were simultaneously stacked by the cranes up to the maximum height of 15 meters. After all the speakers had been listened to, the visitors were divided into small groups and allowed to go on a tour of the warehouse.

During the tour, visitors got to see the warehouse up close and ask questions they had about how the warehouse works. Participants were given the opportunity to look more closely and get detailed explanations of the grippers and cranes, see how the loading takes place when paper rolls are loaded from trains to conveyor belts and then end the tour at the loading docks where they got to see how paper rolls come out of the warehouse to be stuffed in containers that are sent out to the world.

This type of investment provides increased competitiveness for the paper industry, which is essential in central Sweden, and this in turn strengthens the region's trade both nationally and internationally, said Fredrik Svanbom, CEO of Gävle Hamn

PASO DE LOS TOROS, Uruguay , Sept. 3, 2020 (Press Release) -While construction of its second pulp mill in Uruguay goes on at full speed, UPM is hard at work addressing concerns associated with such large-scale projects, including community safety, housing and infrastructure, and safeguarding the environment.

Construction is well underway for UPM’s second pulp plant in Uruguay. The three-year project began following an investment decision in July 2019 and will be completed in 2022. The associated construction projects in central Uruguay and Montevideo now consist of 16 building sites, meaning the new mill is already boosting the local economy and regional development. This is also allowing for the creation of new opportunities for individuals and businesses.

UPM is investing USD 3 billion into the construction of the mill, in the province’s infrastructure and a pulp terminal at the port of Montevideo. Among the many improvements related to the project will be the construction of new rail lines connecting Durazno with the port of Montevideo. Once the mill is fully operational, the mill together with the entire value chain including forestry, wood sourcing and logistics operations is estimated to contribute about 2 percent of Uruguay's GDP.

The new pulp mill will also create about 10,000 new jobs throughout the country, contributing USD 170 million annually in tax revenue and social security payments. But while the economic benefits of the new project are clear, they do create visible changes in the region.

The impacts of a mega project

Increased traffic and accommodating the 6,000-person workforce are among the two biggest concerns around the project for the local population identified in the Social and Environmental Impact Assessment of the new pulp mill carried out by UPM. However, Magdalena Ibañez, UPM Uruguay’s Community Development Manager, says the company has implemented mitigation plans in cooperation with local and national authorities, as well as expert organisations.

In order to prevent the influx of full-time construction workers from overwhelming any single location, UPM has arranged for permanent and temporary housing construction in four different localities.

Paso de los Toros will host 2,600 workers, with neighbouring Pueblo Centenario housing 1,000. Roughly 30 kilometres south of the construction site, Carlos Reyles will be home to around 400 workers and Durazno will host another 1,200 workers. Additionally, the localities will benefit from the infrastructure done for the temporary housing plus 60 permanent houses.

“We have implemented a housing plan, which includes permanent houses that will be built and later be left in the community for the state to make use of,” says Ibañez.

“There are also temporary accommodations, which are placed as the workers arrive and removed after they leave,” she adds. “What will remain for the Uruguayan state will be the associated infrastructure for these temporary homes, including electricity and sanitation.”

Ibañez said that UPM was also working with the local government to prevent traffic associated with the project from saturating the region’s roads. A new transportation service has been created for the transfer of workers to and from the construction site. Each location will have the necessary amount of buses to transport all the workers considering the shifts and characteristics of each boarding point.

“Where the workers are going to be accommodated, there are different bus terminals and then there are stops that have been set up together with the state and local authorities,” says Ibañez. “Most of the workers are using this service to go to work.”

Keeping the community safe

While the additional traffic has been minimised, UPM recognises that the increase still comes with new road safety challenges. As a result, UPM is working with the NGO Desem Junior Achievement to offer road safety talks in local schools and the Automobile Club of Uruguay, a non-profit, to host further traffic safety events.

However, road safety is not the only component of local safety that is of concern to UPM: concerns over sexual exploitation, which is a risk typically associated with large-scale construction projects worldwide, have been brought up by the community.

“At some point, UPM heard that call from the community and went out to look for one of the NGO civil associations that have been working strongly on the subject,” says Natalia Guidobono, a sociologist at El Paso and the coordinator of UPM’s project for the prevention of child and adolescent sexual exploitation.

To tackle this thorny issue, UPM has agreed to fund the first part of a two-pronged campaign, aimed at informing the workforce about the harm that these types of illicit activities inflict on a local community as well as educating members of the community on how to identify and prevent sexual exploitation.

“I believe that UPM, like any company that is set up, is going to generate a series of impacts at the community level,” says Guidobono. “Therefore, they have an important role in being able to prevent sexual exploitation and be attentive to other possible side effects of their presence.

“We understand our operations from a comprehensive perspective, including a responsible commitment to local communities. We are on a path of joint work and dialogue with local organisations and leaders to find the most appropriate ways to mitigate the potential impacts of the construction of the pulp mill,” says Ibáñez.

Protecting the environment

Along with safety for the community, protecting the environment is another issue for the local population and Uruguayans at large. However, UPM has learned from previous projects and has a plan to mitigate that as well. As part of the permit process, UPM has submitted an environmental impact assessment required by the Uruguayan authorities.

The mill is designed to fully meet strict Uruguayan environmental regulations as well as international standards and recommendations for modern mills, including the use of the latest and best available proven technology (BAT). The effectiveness of these measures will be closely watched and, similar to what is practised at the UPM Fray Bentos plant, the new mill’s environmental performance will be verified with comprehensive and transparent online monitoring.

The company has already committed to participating in Uruguayan government’s Rio Negro initiative, providing $1.5 million a year for the next 20 years and providing technical help in order to assist with the initiative and keep the local environment clean.

Additionally, Bruce Rodgers, a consultant at Ecometrix who helped advise UPM during the planning phase, expects the environmental impacts to be minimal. He partially attributed this to the exceedingly high environmental standards set by the Uruguayan government.

“UPM will construct a wastewater treatment plant that uses the best available technology,” says Rodgers. “In other words, they will build a spectacular treatment system. It will treat the waste materials and produce a very high-quality effluent that will conform to the high standards that Uruguay has set for the mill.”