Little steps: big impact

A food packaging producer saves expensive fiber and optimizes chemical additives with a BTG solution.

A major producer of molded board for food containers and tailored industrial packaging uses predominately recycled fiber, with groundwood and Kraft pulp added for drainage and strength. But Kraft pulp and chemicals are expensive, so a significant cost advantage is gained by minimizing the consumption of Kraft fibers and optimizing additive chemical consumption. That is where BTG stepped in with a solid measurement and control solution and an excellent ROI.

To this end, BTG performed first three process analyses from the thick stock to the headbox. This was supplemented by process and product training. Based on this analysis, the process was improved step-by-step, avoiding radical changes and providing a budget-friendly implementation plan for the mill with no major up-front expenditures.

The mill installed new BTG consistency sensors on each vat former, thus providing selective and accurate consumption of each raw material. As a result, the consistency control was much tighter. Consistency stability at the mixing chest was improved and the dosing points for chemicals into the mixing chest were optimized. The mill invested also in a Mütek Particle Charge Detector and a System Zeta Potential which measured dissolved charge and fiber charge. These measurements defined the results of chemical dosage.


The tighter consistency control led to better process stability and raw material saving. Charge measurements furthermore optimized chemical consumption. The results for one grade recipe included:

  • The use of Kraft fiber was reduced by 37% and partly replaced with a less expensive recycled fiber.
  • Dosage of sizing agent was optimized using a better dosing point recommended by BTG. One chemical additive was eliminated totally.
  • Board weight was reduced by 10%.
  • The total yearly savings were 170.000 €.

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