Reduced CO2 emissions, relief of electricity grid and steering on energy prices go hand in hand

Folding Boxboard Eerbeek switches to flexible power production

Folding Boxboard Eerbeek has been producing the electricity needed to produce their folding boxboard with its own combined heat and power plant for many years. The cogeneration plant, which runs on natural gas, is now equipped with innovative software. This will make it possible to make the best choice based on highly fluctuating energy prices: producing electricity yourself using natural gas or buying electricity from the regular power grid.

The switch to this flexible power generation has positive consequences in several areas. When electricity prices are low, Folding Boxboard Eerbeek’s natural gas turbine automatically switches back and the system itself chooses to buy electricity from the regular power grid. This leads to a reduction in local CO2 and nitrogen emissions and is an important contribution to the Netherlands’ desired switch from natural gas to sustainably generated electricity (electrification). Are electricity prices high and threatening to overload the power grid (grid congestion), something that is increasingly common in the Netherlands? Then the system can temporarily switch back on its own electricity production using natural gas, and Folding Boxboard Eerbeek contributes to balancing electricity supply and demand. Moreover, the continuous flexible response to the most favourable energy price in each case naturally ensures cost efficiency. With this, Folding Boxboard Eerbeek strives for the continued affordability of sustainably produced folding boxboard for customers in the packaging industry.

Sustainable packaging material, sustainable production

Folding Boxboard Eerbeek sees flexible power production as one of the many steps it wants to take in the coming years in terms of energy efficiency and sustainability. In this particular case, the company is working closely with cardboard producer Sappi Maastricht, which already has experience with flexible power production. The partnership proves that the Dutch paper and cardboard producers are putting their shoulders to the wheel in making their sector more sustainable, both by themselves and together. After all, paper and board packaging materials are made of the most sustainable, eternally renewable and optimally reusable raw material available: wood from sustainably managed forests in Europe. It is therefore natural for the Dutch paper and board industry to also fully commit to making all production processes more sustainable.

The year 2023 was a special and challenging year for our industry. We would like to thank our relations for their trust and cooperation over the past year, together we were able to put our shoulders to the wheel. We wish everyone happy holidays and look forward to 2024 with confidence. We have made a short movie for the end of 2023.

After more than a year of technical and practical preparations, the Eerbeek Water Roundabout (The Netherlands) pilot was officially launched in September. On the premises of Industriewater Eerbeek (IWE), a test installation of a closed, circular water management system will run until the end of 2023. This pilot will investigate whether a ‘full scale’ installation is technically and financially feasible. The aim is to connect the first paper mill to the circular system by mid-2026. The Water roundabout Eerbeek is committed to making the paper industry more sustainable and almost 100% circular reuse of industrial wastewater. This will ensure paper and cardboard mills around Eerbeek and Loenen continue to have sufficient water for their production processes in the future, while drastically reducing their water footprint.

The project was initiated and developed by Folding Boxboard Eerbeek together with the two other paper mills from Eerbeek that also own IWE; a fourth paper mill from nearby Loenen has committed to the test as a party. Together, the four paper mills have a highly water-intensive production process and, in making water consumption within Waterrotonde Eerbeek circular, could together save 3.6 million m3 of groundwater annually. This is equivalent to the consumption of 22,000 households. Moreover, the technology could be the answer to the impending shortage of clean drinking water due to climate change and population and economic growth.

Careful handling of groundwater: our responsibility

This summer, several heat records fell worldwide: including Western Europe. Despite the relatively wet spring of 2023, dehydration is a growing social problem. The sandy soils of the Veluwe (Eerbeek borders the Veluwe nature reserve) also suffer from longer periods of low precipitation. “The paper industry is very aware of the impact that current groundwater consumption has. Therefore, from our social responsibility, we now want to do everything possible to reduce groundwater extraction as much as possible. With this in mind, the Eerbeek Water Roundabout was born in 2022,” says William Suijkerbuijk, project director and the brains behind the Eerbeek Water Roundabout.

The Water Roundabout can contribute to a sustainable ecosystem with an eye for people and the environment. Moreover, with the project we want to anticipate upcoming regulations regarding discharges on surface water. In Water roundabout Eerbeek, all these ambitions come together.”

Ultimate goal: zero liquid discharge

Industriewater Eerbeek (IWE) has been treating excess process water from paper mills Folding Boxboard Eerbeek, Stora Enso De Hoop Mill and Neenah Coldenhove since its establishment in 1960. Residual streams such as lime, sludge and biogas are reused by IWE, and the organisation also aims to further expand circularity in terms of energy and auxiliary material use in the long term. The ultimate goal is zero liquid discharge. This means almost 100% reuse of wastewater from all four plants and full utilisation of available raw materials,” Suijkerbuijk said.

Future Eerbeek water roundabout

Until the end of 2023, various, innovative technologies for water treatment will be extensively (scientifically) tested in the pilot Water roundabout Eerbeek. Important precondition is the scalability of the project; various scenarios are being considered. Based on the various tests and results, as well as the financial feasibility, a choice of technology to be implemented will be made in early 2024. Further process automation and the construction of the plant itself will follow in 2025, and then the various plants will be connected step by step. The aim is to be the first to connect Folding Boxboard Eerbeek to this Water Roundabout in 2026.

This year, our French customer Posson Packaging was nominated with a packaging made of our Excellent Top Strong from our Baiersbronn mill for KEVAS Rhum Arrangé. The design makes the Kevas Rhum visible through plastic-free windows, meaning the entire packaging is made of our folding boxboard. With different ways to display the products, it delivers a unique aesthetic appeal on shelves to stand out from similar products.

We are very pleased to announce that Posson’s Packaging entry, with their packaging for Kevas Rhum was this year’s winner in the Food & Drinking category Pro Carton – The association of carton and cartonboard manufacturers. The Jury found the whole entry to be an impressive design that perfectly and elegantly displays the products inside the box while telling a story about the contents. The intricate construction of the design includes several panels in the boxes, giving it a unique and sophisticated look. The durable yet playful nature of this design was highly appreciated by the jury.
Naturally, we are very happy with this award, which is a confirmation of the quality of our products. Interested in designing your packaging with our virgin fiber folding boxboard products? Contact Laurent Heurckmans