New Papermaking Method Could Revolutionize the Industry

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Innventia, a Stockholm, Sweden-based research institute, is continuing to revolutionize the paper business. Its research work has now produced a new method that will result in a stronger paper with lower production costs and reduced raw materials consumption. This dream scenario has now become a reality for many companies in the paper business, Innventia notes.

"For a paper mill that produces 450,000 metric tpy of the new paper, this technology means an annual savings of approximately 120 million Swedish kronor," says Daniel Söderberg, research manager and initiator at Innventia and the person behind the previous work.

The Aq-Vane technique is derived from the aircraft industry. It deals with the separation of fiber layers before they are joined together to form the paper. "This technique uses a thin layer of water to stabilize the fiber layers and consequently form an even flow while they are being joined together. This prevents the layers from blending with each other. This means that it is now possible to keep the layers separate as well as to control the precise properties that are wanted in a paper," Söderberg says.

For a product such as the IKEA catalogue, approximately 200 million copies of which are distributed each year, this means enormous savings, Innventia points out. For the papermaking industry as a whole, this implies a savings in billions of kronor. "We've tailor-made a new kind of uncoated paper, which is the same type as that used in the IKEA catalogues. By putting finer fibers in the surface and coarse fibers in the middle of the paper we're able to save up to 10% in costs on fiber raw materials and energy," Söderberg explains.

Earlier this summer, Innventia began leading BoostEff, an EU project with a total budget of EUR 11 million, to demonstrate the industrial and economical potential of the method. Using Aq-vane, with its possibilities for advanced dosage, Innventia, in collaboration with Finland's Stora Enso, is developing the kind of paper that is used in catalogues and magazines.

"This project also signifies a completely new way of working," says Söderberg. "The starting point in the project is three existing industrial production units, one of which belongs to Stora Enso. Using these, the possibilities of the new technique, together with existing techniques, are being adapted to demonstrate the potential product and the production process involved. The results from the project are going to be used as a basis for three investment projects involving technical specifications and economical results.
The Aq-vane technique has the potential to generate increased profits based on the form of savings in the fiber raw materials and energy.

"Within BoostEff several companies and institutes from around Europe are collaborating with us at Innventia," Söderberg continues. "When the project comes to an end in 2013, the technology will also be available to the rest of the industry, giving the opportunity of an increased profitability and, most of all, an improved paper."