The project has reduced CO2 emissions by more than a quarter, and saves 55,000 tonnes of CO2 per annum.

Smurfit Kappa explained that the redesign of the site’s multi-fuel boiler had resulted in the 500,000tpa mill now being powered by a combination of its own biogas (a by-product of its circular water treatment plant), natural gas “and the residual materials or so-called ‘rejects’ which occur in the paper recycling process that would otherwise be considered waste”.

The mill makes containerboard and specialises in brown testliner, high performance recycled fluting and recycled fluting.

Zülpich also uses rejects from the group’s Parenco and Roermond mills in the Netherlands as part of its circular business model approach.

Pim Wareman, CEO of the Smurfit Kappa Recycled Paper Cluster, said the project was “yet another example of how, at Smurfit Kappa, sustainability is part of our DNA”.

“The project shows that economic efficiency and sustainability are by no means mutually exclusive but can go together hand in hand taking the mill on a very positive journey.” 

Further sustainability initiatives are planned for Zülpich.

Packaging giant Smurfit Kappa has set a goal of achieving a 55% intensity reduction in fossil CO2 emissions by 2030 and “at least net zero CO2 emissions by 2050”.