The modernization of paper production at the Eilenburg site presented a particular challenge for Model Sachsen Papier GmbH. The conversion from graphic papers to corrugated base paper required not only the adaptation of the hall ventilation system, but also a climate-friendly response to significantly higher energy demand.
Together with airinotec, the company implemented a concept based on intelligent heat recovery, optimized control strategies and modern automation technology, drastically reducing primary energy consumption and making an important contribution to decarbonization.
Sustainable production in the heart of Europe
Since August 2021, Model Sachsen Papier GmbH has been part of the internationally active Model Group. Built in 1993/94, the Eilenburg mill is one of the most modern paper production sites in Europe. Following the conversion, it produces approximately 625,000 tonnes of corrugated base paper per year using 100% recovered paper. The focus on basis weights ranging from 70 to 120 g/m² supports the growing demand for lighter packaging solutions.
Increased humidity and thermal load
The conversion to corrugated base paper significantly changed the climatic conditions inside the production hall. Higher moisture release and increased thermal load required the supply air volume in the paper machine hall to be raised by 560,000 m³/h, increasing heating demand by more than 50%.
The finished goods warehouse and the microflotation system each required an additional air volume of 80,000 m³/h. In total, approximately 1.5 million m³/h of air had to be heated. Without an efficient energy concept, this would have resulted in a substantial increase in primary energy consumption, in conflict with Model’s sustainability targets.
The task assigned to airinotec
AIRINOTEC was commissioned to adapt the hall ventilation system while minimizing primary energy consumption. Rather than relying on additional fossil energy, the objective was to use the waste heat already available from the production process more effectively.
This required the optimization of the existing process hot water system, PWW, the expansion of the heat recovery system and the implementation of an intelligent control strategy capable of coordinating heat recovery, supply air units and the PWW system throughout the year.
Project implementation
airinotec handled engineering, supply, installation and commissioning. The project comprised four 100,000 m³/h supply air units and one 80,000 m³/h exhaust air unit for the paper machine hall; one supply air unit and four exhaust fans for the finished goods warehouse; and 80,000 m³/h supply and exhaust air units for the microflotation system. The heat recovery system was upgraded to recover more waste heat, while the EnergyOpt control strategy maximizes year-round efficiency and reduces pump energy consumption.
“With this project, we have demonstrated how intelligent control strategies and optimized heat recovery can drastically reduce energy consumption. Together with Model Group, we are making an important contribution to the decarbonization of the paper industry,” says Simon Linhardt, Sales Engineer at airinotec.
Benefits and progress towards decarbonization
Despite a 50% increase in air volumes, the modernization of the hall ventilation and heat recovery systems reduced primary energy demand from 27,500 to 7,500 MWh, with heat recovery now covering 90% of the heating requirement. This has significantly lowered CO₂ emissions and operating costs, while the continued use of existing systems has limited investment costs and preserved resources.
The project marks another important step towards climate-friendly production at Model Sachsen Papier GmbH and demonstrates how technological innovation and environmental responsibility can work together, with airinotec providing energy-efficient solutions designed to reduce the long-term CO₂ footprint of paper production.
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