The scenario changed with the introduction of ANDRITZ HyperFlaker technology. By replacing the traditional smooth tooth edges with an innovative serrated design, the ANDRITZ HyperFlaker delivers a broad range of advantages compared with conventional deflakers.
Now patented or patent-pending in both the EU and international markets, these globally unique fillings are available exclusively from ANDRITZ. The design can be installed on almost any disc, ring or conical deflaker, including older units and machines supplied by other manufacturers.
Upgrading with HyperFlaker rings changes the cost, quality and environmental impact of the deflaking process. Technology increases flake shearing and reduces fibre clumps, producing cleaner and more homogeneous stock while requiring less energy to achieve the same result.
The solution can be applied to broke-handling systems and chemical or mechanical pulp stock-preparation lines across the full range of stock consistencies, for coated and uncoated grades, virgin or recycled fibres, wet-strength papers and tissue.
Since deflaker fillings must already be replaced periodically, HyperFlaker technology can be installed without additional downtime or extra expenditure.
Numerous mills have already adopted the solution and report benefits including substantial reductions in repulping times, lower or even zero consumption of certain chemicals, such as dissociating agents, reduced energy use or increased production at unchanged energy consumption, the possibility of using less expensive raw materials and improved optical properties in the finished paper.
The results achieved so far are significant. However, with more than 2,000 stock deflakers operating in paper mills worldwide, the industry still offers considerable potential to improve efficiency and product quality while reducing costs and carbon footprint.
Successful HyperFlaker performance at Lucart Porcari, Italy
Among the customers already benefiting from ANDRITZ HyperFlaker technology is Lucart’s tissue and flexible-packaging mill in Porcari, Italy. The fast-growing group has expanded across Europe in recent years and has repeatedly demonstrated a forward-looking approach.
Lucart operates the only mill in Italy that recycles Tetra Pak® cartons into paper, has made substantial investments in solar energy and has collaborated for several years with the IMT School for Advanced Studies Lucca on successful research into the recycling and reuse of paper-mill sludge.
It is therefore consistent with this approach that Lucart also adopted HyperFlaker technology at the Porcari site, achieving a clear improvement in product quality on its MG paper machine PM 3.
“Whenever I walk through the refining room at Lucart Porcari and see the HyperFlaker at work, it reminds me that we at ANDRITZ are contributing to the mill’s many ambitious targets,” explains Erika Sboarina, ANDRITZ Country Manager Italy. “We never stop looking for engineered solutions capable of increasing effectiveness and sustainability, whether through a major rebuild or, as in this case, a patented new spare-part concept. Whether the project is large or small, our passion and commitment remain the same”.
Gianluca Simi, Senior Plant and Process Engineer at Lucart Porcari, adds: “Every milestone marks a new beginning: ANDRITZ contributes to this journey, day by day.”
The mill received its first set of HyperFlaker fillings in late 2025. Lucart subsequently placed additional orders, not only for the Porcari site, but also for another mill within the group.
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