{"id":10113,"date":"2025-10-06T11:20:22","date_gmt":"2025-10-06T09:20:22","guid":{"rendered":"https:\/\/www.cartaecartiere.com\/?p=10113"},"modified":"2025-10-06T11:20:22","modified_gmt":"2025-10-06T09:20:22","slug":"the-electric-revolution-in-papermills-is-a-zero-emission-future-possible","status":"publish","type":"post","link":"https:\/\/www.cartaecartiere.com\/en\/the-electric-revolution-in-papermills-is-a-zero-emission-future-possible\/","title":{"rendered":"The electric revolution in papermills: is a zero-emission future possible?"},"content":{"rendered":"\n

by: Francesco Ureni, Head of R&D, Toscotec<\/em><\/p>\n\n\n\n

In an industrial landscape increasingly prioritizing sustainability, this shift is more than just an environmental goal \u2013 it is an economic and regulatory imperative that is actively reshaping the future of this key sector. This is not merely a voluntary choice, but rather a mandate from Brussels. <\/p>\n\n\n\n

The European Green Deal and the Fit for 55 package leave no room for interpretation: the goal is to reduce CO\u2082 emissions by 55% by 2030 compared to 1990 levels, alongside a gradual phasing out of fossil fuels. <\/p>\n\n\n\n

Papermaking companies are now compelled to make a definitive shift, accelerating the transition toward fully electric technologies and significantly reducing reliance on natural gas and other fossil fuels.<\/p>\n\n\n\n

\"\"<\/a>
Detail of the Toscotec full-electric batteries in Fortissue.<\/figcaption><\/figure>\n\n\n\n

In this context, Toscotec is further establishing itself as a pioneering company. Technological innovations are offered to guide clients in the transition toward zerodirect- emission plants. <\/p>\n\n\n\n

With a strong commitment to Research and Development, a wide range of cutting-edge and flexible solutions is provided, ideally suited to support partners in achieving their sustainability objectives. Toscotec\u2019s R&D department bases its strategic approach on three main pillars: sustainability, reliability and flexibility.<\/p>\n\n\n\n

First, it is key to ensure a tangible and measurable reduction in emissions by directly implementing technological changes within the mill. Second, new electrified technologies are integrated into production cycles with the same reliability as traditional solutions. <\/p>\n\n\n\n

Finally, the third pillar addresses the biggest challenge: designing machinery and systems capable of operating in various energy environments, whether in hybrid or full-electric mode, to meet the specific needs of each production site.<\/p>\n\n\n\n

Field data from operational plants directly guide development and foster a continuous feedback loop between engineering and real-world performance. Software-automation integration is another key area of focus. Thermal control algorithms are precisely calibrated to respond in a predictive manner to load fluctuations, significantly reducing waste and improving the final product quality. <\/p>\n\n\n\n

In addition, collaboration with universities and European research centers on joint industrial decarbonization projects aims not only to develop new technologies but also to validate their impact in terms of ROI and TCO.<\/p>\n\n\n\n

Fortissue<\/strong>, in Portugal, is now considered a European model for the green energy transition within the tissue paper industry. This mill, entirely designed, installed and started up by Toscotec, stands as the first fully electric, industrial-scale tissue paper mill. It functions without the need for direct on-site combustion; thus, it paves the way for a cleaner future in papermaking.<\/p>\n\n\n\n

\"\"<\/a>
Toscotec and Fortissue: start-up day.<\/figcaption><\/figure>\n\n\n\n

All systems within the Energy & Environment Department are powered by electricity, with an optimized configuration designed to leverage local renewable sources and drastically cut CO\u2082 emissions. Fortissue serves as a real-world, open-air laboratory. <\/p>\n\n\n\n

The rebuild project, through Energy Pack products, allowed the successful testing and demonstration of the immense potential of electrification within the industry.<\/p>\n\n\n\n

Equipped with Toscotec\u2019s TT NextPress shoe press, this high-performance machine has been completely upgraded to make tissue production more sustainable. A fully electric air system configuration was installed through the TT e-powered Hood (with natural gas burners remaining for backup), featuring multiple heat recovery stages. TT Swing ensures maximum flexibility, offering a variety of choices from full cascading mode to hybrid configuration, depending on specific production needs.<\/p>\n\n\n\n

Meanwhile, TT Turbodryer utilizes a portion of the hood exhaust gases to enhance the shoe press\u2019s effectiveness and increase water removal during pressing. Finally, the new TT e-powered SteamBooster generates 100% of the steam required for the TT SYD Steel Yankee Dryer.<\/p>\n\n\n\n

\"\"<\/a>
Scheme of the full-electric configuration.<\/figcaption><\/figure>\n\n\n\n

A significant portion of this steam is directly recovered from the hood exhaust heat, with the remainder generated by electric heaters. <\/p>\n\n\n\n

The Portuguese plant\u2019s success proves how thorough thermal flow engineering, combined with digital integration, enables performance that rivals \u2013 and in some instances even surpasses \u2013 that of conventional plants. For example, the absence of a chimney for the electric boiler immediately yields approximately 10% saving. <\/p>\n\n\n\n

The hood can also achieve consumption reductions due to the absence of combustion air. This project served as a powerful market benchmark, demonstrating that the electric papermill is no longer a distant, futuristic idea, but a concrete and competitive reality today.<\/p>\n\n\n\n

Another significant example comes from a recent turn-key plant supply in France, where a complete tissue plant featuring new-generation electric hoods from Toscotec was recently commissioned by MPH1865<\/strong>. This represents a forward-thinking strategic choice, offering lower environmental impact, total control over energy costs, and alignment with future decarbonization policies.<\/p>\n\n\n\n

The electric hood installed at MPH1865 stands out for its high efficiency and ability to dynamically adapt the drying curve, with the future potential to leverage the control system\u2019s predictive intelligence. This results in consistent product quality and a significant reduction in specific thermal energy consumption. <\/p>\n\n\n\n

Furthermore, the supervision interface allows real-time monitoring of energy parameters and demand response activation strategies during peak periods on the electrical grid. The projects at Fortissue and MPH1865 are no longer exceptions; they now serve as benchmarks for future installations. Interest in full-electric solutions is clearly growing, driven by public incentives, increased availability of renewable energy sources and progressively stringent sustainability policies from major retailers and end-users alike. <\/p>\n\n\n\n

Toscotec is not just a technology supplier: it is a strategic partner in the paper industry\u2019s decarbonization journey \u2013 offering an integrated approach to energy transition. The key challenge now lies in making these groundbreaking solutions scalable, replicable and economically sustainable, all while consistently ensuring quality, competitiveness and production continuity within the sector. <\/p>\n\n\n\n

MIAC 2025 will be the key event to discuss these new developments. Direct evidence, tangible performance data, and state-of-the-art projects will be presented to clearly demonstrate how the papermill of the future is truly \u201ccharged\u201d with innovation.<\/p>\n\n\n