Steam consumption for mass starch preparation at Hamburger Containerboard Gelsenkirchen reduced by over 80%.

The starchPERFORMER from PGA Anlagenbau, a member of the IBS Paper Performance Group, is setting new standards in mass starch preparation at Hamburger Containerboard's Gelsenkirchen site. The patented technology impresses with a thermomechanical process that both drastically reduces resource consumption and significantly improves the quality of the processed starch. The successful implementation is an impressive example of the potential of this technology with demonstrable successes.

Here are the key figures:

• 82 % less steam consumption
  and thus an improved CO₂ balance of over 2,500 tons per year.
   
• 70 % less fresh water consumption 
  thanks to two-stage dilution with clear filtrate.
   
• 70 % higher solids content in the storage tank 
  this creates additional buffer capacity and increases plant availability.
   
• 64 % fewer unplanned interruptions 
  resulting in more stable production and a reduced reject rate.
   
• Annual savings of € 500,000 
  through reduced energy and water consumption. The drive power required for the starchPERFORMER is already taken into account here.

The improvement in paper properties is particularly noteworthy: The starch processed with the PGA starchPERFORMER contributes to more stable processes and in some cases even to better end product properties - a clear plus point for producers of packaging papers and plasterboard base papers such as those in Gelsenkirchen.

Erik Musaev, Manager Center of Investment & Technology at Hamburger Containerboard, is highly satisfied with the project result: “The starchPERFORMER in the mass starch preparation has exceeded expectations in every respect - both in terms of efficiency and quality. The investment has paid for itself in less than a year.”

From conventional to consequently modern

Conventional starch preparation using jet cookers is still widely used in the paper industry - despite significant weaknesses: high steam consumption (4 - 2.2 kg per kg of dry starch), low cooking concentrations (4.5 - 8 %), inhomogeneous quality of the cooked starch and deposits in the residence areas. The starch is sheared only once in the steam access area.

The PGA starchPERFORMER breaks with these limitations. With cooking concentrations of 15 - 25 %, steam consumption can be reduced to 1.2 - 0.7 kg per kg of dry starch. The cooking principle is based on a thermomechanical process with multiple shearing, which ensures a fully cooked, homogeneous and reproducible starch quality. The technology also completely prevents deposits - a major advantage for continuous operation and plant safety.

Flexibility meets sustainability

Another outstanding feature of the PGA starchPERFORMER is its flexibility: all types of starch can be processed - and that for mass and surface starch. Furthermore, each machine size can be operated in a throughput range of 1:5. The technology not only allows a significant reduction in steam, starch and fresh water consumption, but also increases operational reliability in the event of unplanned interruptions thanks to the higher possible storage concentration of 8% in the downstream storage tank.

Conclusion and outlook

The PGA starchPERFORMER is more than just a technology - it is a forward-looking step for paper mills that take their sustainability goals seriously and at the same time want to increase the efficiency of their processes. The positive experiences at Hamburger Containerboard Gelsenkirchen are encouraging for scaling: a rollout to other mills in the Group is already being examined.