Energy, decarbonization and competitiveness in the paper industry

The conference will be moderated by Alessandro Bertoglio of Assocarta, who is responsible for the Association’s activities related to energy, climate and transport, with a particular focus on energy efficiency and decarbonization issues affecting the paper industry.

At the European level, discussions are currently underway on the revision of the ETS (Emissions Trading System), with potential changes affecting both the 2026-2030 period and the post-2030 framework. Key topics under consideration include the revision of benchmarks, the functioning of the Market Stability Reserve (MSR), and carbon border adjustment mechanisms.

In this context, the Italian Ministry of Environment and Energy Security is actively involved in defining Italy’s position and proposing possible adjustments to the system, with the aim of achieving European climate targets while safeguarding the competitiveness of national industry.

In today’s paper industry, accurately evaluating projects aimed at improving energy efficiency and reducing environmental impact has become increasingly important, particularly for small- and medium-sized production sites.

By increasing the dry content before the drying section, high-load shoe presses significantly reduce thermal energy demand, enabling mills to lower steam consumption and achieve substantial reductions in CO₂ emissions.

Through the presentation of two recent press section rebuild projects on paper and board machines, this session will cover different machine configurations and paper grades, demonstrating the versatility and reliability of Voith-Toscotec high-load shoe press retrofit solutions.

Each case study highlights how advanced press technology can significantly improve sheet dryness after pressing, delivering measurable gains in overall energy efficiency and machine performance.

The presentation will illustrate Toscotec’s technical approach, implementation strategies, and the operational results achieved by customers following start-up, with a focus on the key factors driving energy savings and carbon footprint reduction.

Participants will gain practical insights into how targeted press section upgrades can deliver significant sustainability benefits while simultaneously improving machine runnability and production economics.

Sustainability is at the forefront of innovation in the tissue industry, as energy consumption and environmental impact have become critical concerns for both producers and machine suppliers. Today, addressing climate change and advancing sustainability are not only environmental imperatives but also key drivers for achieving significant cost savings, making them essential factors in ROI calculations and top priorities for customers.

A major contributor to TAD energy demand is the large volume of water that must be evaporated during production. Reducing this water load is therefore a central objective: every percentage point increase in sheet solids entering the TAD drying process translates into substantial energy and cost savings. For example, even a 1% increase at a solids content of 25% results in a significant reduction in the amount of water that must be evaporated.

ANDRITZ has developed and patented a new pre-dewatering module, originating from its pilot facility in Graz (TIAC), which increases sheet solids before the first TAD drying stage without compromising the final paper properties. This breakthrough makes TAD technology more sustainable and energy-efficient in established markets while also creating new opportunities worldwide.

Most importantly, this technology has already been successfully implemented, supported by robust operational data and excellent results. These outcomes have been repeatedly validated at the PrimeLine TIAC (Tissue Innovation and Application Center) pilot facility. The concept has been designed with flexibility in mind, allowing existing TAD machines to be upgraded with this solution. As a result, it represents an attractive option for both new installations and brownfield projects seeking to improve sustainability, efficiency, and profitability.

With the development of shoe presses, high-pressure cylinders, and high dew point hoods, the efficient use of energy in the paper machine drying section has become increasingly complex. Traditional approaches to energy utilization are no longer sufficient; it is now essential to design the steam system in conjunction with the hood and other heat sinks within the papermaking process.

This study focuses on improving thermal efficiency, reducing steam losses, and enhancing condensate recovery through a combination of system analysis, process modeling, and practical design considerations. Key areas examined include steam pressure control, condensate removal philosophy, and the most effective use of the sensible heat contained in dryer condensate.

The presentation explains the limitations of conventional system design practices and identifies the changes required to meet the performance and efficiency demands of modern paper machines.

The drying process has historically been one of the main contributors to energy costs and environmental impact in tissue production. However, the adoption of structural efficiency improvement projects has often been limited by technical complexity, significant investment requirements, and difficulties in accessing incentives for high-efficiency cogeneration.

This presentation will examine a real case study developed with a leading industrial partner, in which the integration of direct exhaust gases from a Solar Turbines gas turbine into the drying hoods enabled a significant reduction in energy consumption and emissions, while maximizing the economic benefits associated with high-efficiency cogeneration certificates through a flexible contractual model and a certification process approved by the Italian Energy Services Operator (GSE).

The presentation will also highlight the flexible operational solutions developed by Solar Turbines, designed to ensure high industrial and economic performance even in environments characterized by strong energy price volatility and increasing geopolitical uncertainty.

The paper and tissue sector is among the most energy-intensive industries within Italian manufacturing, with a high and continuous demand for thermal energy. The traditional reliance on natural gas now exposes paper mills to structural price volatility, amplified by geopolitical tensions and the increasing penetration of photovoltaic generation, which causes significant fluctuations in electricity prices on an hourly basis.

In this context, the presentation provides a technical comparison of the main technologies available for the decarbonization of thermal utilities — gas-fired cogeneration, biomass, high-temperature heat pumps, and Power-to-Heat systems — analyzing their operational flexibility, economic risk profile, and potential for integration.

The objective is to outline a methodological approach for building a resilient thermal energy portfolio capable of taking advantage of periods with low or negative electricity prices while reducing exposure to natural gas market volatility, in line with industrial decarbonization targets.

The key message is that future thermal utility generation cannot rely on a single technology. Instead, it will require the integration of multiple solutions to maximize market opportunities and minimize exposure to external risks, including geopolitical uncertainties.

The new design of the OraStream automatic vacuum valve, developed by Oradoc, introduces an advanced control system that enables precise modulation of vacuum levels through a fast-response automated actuation mechanism. This solution simplifies the control system while ensuring high reliability and consistent performance. Available in both two-way and three-way configurations, the valve is fully interchangeable with traditional models without requiring modifications to the existing plant.

In the project carried out at Cartiere di Guarcino, the medium-vacuum automatic valves on paper machine MC1 were replaced with OraStream valves installed on the DuoFlow boxes downstream of the breast roll. The previously installed valves suffered from instability, clogging, mechanical failures, and frequent maintenance requirements.

The adoption of OraStream technology improved vacuum stability, drainage during the early stages of sheet formation, and sheet uniformity, while also reducing maintenance-related downtime. The result was a measurable improvement in operational stability, production efficiency, and paper quality.