Smurfit Kappa Hoya Papier und Karton GmbH

Smurfit Kappa Hoya Papier und Karton GmbH
Präsentation vom 19.05.2010
anlässlich 2. AG-Sitzung Energieeffizienz in KMU - Klimaschutzkonzept LK Nienburg
Referent: Torsten Ostermann
Smurfit Kappa Hoya Papier und Karton GmbH
2
History
1957
In 1953 the Container
Corp. Of America
founded the Europa
Carton AG.
In 1957 the Hoya board
mill was build.
3
History
In the beginning the
mill produced
containerboard,
later Folding
Boxboard
History of Hoya Paper
In 1990 was the start up of
PM 2
Once built for 150,000 t/y,
the machine is able to
produce more than
290,000 t/y containerboard
today
5
Site overview today
6
The owenership of Smurfit Kappa Hoya changed several times
Container Corp. of America
CBI (Consolidated Bathurst incorporated)
Stone Container
Smurfit Stone Container
Smurfit
7
Smurfit Kappa
Management System
8
! Internal GMP Certificate
Organisation
A split mill within the Smurfit Kappa organization
European Packaging - Paper
Recovered
Recovered
Paper
Paper
Virgin
Virgin
Containerboard
Containerboard
- Sweden
- France
- Austria
- Slovakia
European Packaging - Corrugated
Recycled
Recycled
Containerboard
Containerboard
RPE
- Netherlands
- Germany
- Czech Rep
South Eur
- France
- Spain
- Italy
Benelux
Benelux
Central
Central Eur
Eur
France
France
Germany
Germany
Ireland
Ireland
Italy/Poland/
Italy/Poland/
Russia
Russia
Nordic
Nordic
Spain/Port
Spain/Port
UK
UK
UK
European Specialties
10
Paper
Paper Sacks
Sacks
Solid
Solid Board
Board
Bag-in-Box™
Bag-in-Box™
Carton
Carton
Latin America
Colombia/
Colombia/ Ecuador
Ecuador
Costa
Costa Rica
Rica
Mexico
Mexico
Argentina
Argentina
Chile
Chile
Venezuela
Venezuela
Dominican
Dominican Rep
Rep
Puerto
Rico
Puerto Rico
Smurfit Kappa RPE
Paperdivision
Fibre
Fibre supply
supply
Paper
Recycled
Recycled
Containerboard
Containerboard
Europe
Mill
Capacity
Roermond Paper
Zülpich Paper
Hoya Paper
Wrexen Paper
Viersen Paper
Morava Paper
530.000 t/a
5,00m / 5,00m / 2,50m
0.000 t/a
5,00m / ,90m
290.000 Kappa
t/a
7,50m
Smurfit
Carton
225.000 t/a
5,00m
77.000 t/a
2,30m
56.000 t/a
2,50m
Total RPE
11
Virgin
Virgin
Containerboard
Containerboard
Recycled
RPE
Paper Machines
Smurfit Kappa Baden Packaging
Smurfit Kappa Hoya Karton
1618.000 t/a
9 paper machines
RPE Paper Mills
Hoya
1,6 Mio t of recycled
containerboard
Viersen
Roermond
Morava
Morava;
Wrexen;
230000; 1 % 58000; %
Hoya; 28 000;
18%
Viersen;
71000; %
12
Zülpich;
32.000; 27%
Roermond;
521000; 33%
Zülpich
Wrexen
RPE Sales Area
Cz ech
S we de n
D e nma r k
3%
2%
4%
Sales 77% Germany & Benelux
Sales 90% Smurfit Kappa Group
S wi t z e r l a nd
F r a nc e
1%
5%
P o l a nd
Ge r m a n y
7%
47%
Belgium
8%
13
Germany
738743
Netherlands
352329
Belgium
131751
Poland
110016
France
74020
Czech
63215
Sweden
50627
Denmark
39224
Switzerland
10306
Slovakia
8364
UK
7260
Austria
4000
Norway
2575
Spain
1070
N e t he r l a n ds
22%
Combining Performance
1
Guidelines
15
Hoya Paper
Start up: 1990
Net sales 2007:
€ 11 Mio
Net sales 2008:
€ 10 Mio
Capacity:
290.000 T/a
FTE:
161
Apprentices:
11
DIN ISO 9001
DIN ISO 1 001
BS OHSAS 18001
GMP (internal)
16
Smurfit Kappa Carton
Specialties Division
Paper Sacks
Solid Board
Bag-in-Box
Carton
Carton
Subdivision Smurfit Kappa Carton
Smurfit Kappa Carton
Smurfit Kappa Hoya Karton
Smurfit Kappa Baden Karton
Smurfit Kappa Hoya Karton
17
Smurfit Kappa Baden Packaging
Subdivision Smurfit Kappa Carton
SK Carton mills
Hoya
• Baden Karton
• 150 ktons
• 150 FTE
• Hoya
• 83 ktons
• 137 FTE
Gernsbach
Weisenbach
18
SK Carton Packaging
• Baden Packaging
• 58 ktons
• 150 FTE
Smurfit Kappa Hoya Karton
Start up: 1957
Net sales2007:
€ 0 Mio
Net sales 2008:
€ 1 Mio
Capacity:
83.000 T/a
FTE:
137
Apprentices:
DIN ISO 9001
DIN ISO 1 001
BS OHSAS 18001
GMP (internal)
19
9
Übersicht
Luftbild Werk Hoya
21
Werks Layout
PM 2
river
weser
WWG
PM
Area: 318.378 m² (incl. WWG)
22
Aktuelle Luftbildaufnahme mit Umfeld der Stadt Hoya
23
Dampf und Energie System
Anual figures:
Electrical power
G2
GT
DT
20,7
36,
29.7
GWh
GWh
GWh
Eigen
86,8
GWh
Fremd
69,0
GWh
Demand 155,8
GWh
Natural gas
6002
6003
6006
208,6
321,0
1 ,1
GWh
GWh
GWh
Demand373,7
GWh
Steam
PM 2, K1-K3
125.000 t
(9,1 barü / 180°C)
PM 2, K5
355.000 t
(66 barü /
Water injection PM 2
2
50°C)
27.000 t
PM , K 2
212.000 t
( 0 barü / 50°C)
Water injectionPM
n.b.
Machines and Equipment
Paper machine PM 2
Recycled containerboard:
Fluting
HP- Fluting
Test liner 2/3
Basis weight: 90 –210 g/m²
Production speed: 50 – 720 m/min
max. 2 t/h gross
Width: 7,5 m (after rewinder)
25
Machines and Equipment
Boardmachine PM 4
VAT former machine
26
!
wet end:
9 forming cylinders
!
width :
2320 mm
!
speed:
370 m/min
!
basis weight:
300 to 550 g/m2
!
furnish:
recovered paper
!
coating
!
finishing:
rod/blade on both
sides
2 duplex cross
cutters; 1 rewinder
SK Carton Product Mix
GD 2 / Hansaboard
DW Basic
GD 3 / TopPrint
GDK, Eurokraft
27
Barrier board
Environmentally friendly barrier board
Grease Guard and Vapor Guard
The environmentally friendly water based
barrier carton
for packaging solutions for the
food, petfood and detergents market
28
Paper Logistics Solutions by Visurgis
Recovered Paper
Paper
Mill
29
Visurgis: Transport Volume Development
1700000 t
1,5 Mio t
1500000 t
1300000 t
1100000 t
900000 t
700000 t
0,57 Mio t
500000 t
1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008
30
Visurgis: Products transported in 2007
28%
Corrugated Paper
120.000 t
Recovered Paper
400.000 t
31
8%
Paper & Board
925.000 t
64%
Bahntransport als Alternative zum Straßentransport
32
Hoya
t
Hoya shipment by rail in ton: 2000-2010
160000
140000
140000
130000
120000
120000
100000
73000
80000
60000
40000
27000
13072
20000
5136
2719
0
1245
224
2003
2004
2005
0
2000
33
2001
2002
2006
2007
2008
2009
2010
Aktualisierte geplante Bahntransporte für Hoya
SK-Hoya railway transports 2000 - 2015
t
20.000 t Erhöhung ab 26.04.2010
180000
160000
140000
120000
100000
80000
60000
40000
20000
0
2000
2001
2002
2003
External Warehouse
3
2004
2005
Paper
2006
2007
Boxboard
2008
2009
2010
2015
Recovered paper
Bahnverladungen nach Schweden + Norwegen 2005 - 2015
t
120000
120000
100000
100000
80000
66600
60000
40000
27000
33000
40000
20000
0
0
2005
35
2006
2007
2008
2009
2010
2015
Geplante Erweiterungsmaßnahmen
36
Voraussetzung / Ziel der geplante Erweiterungsmaßnahmen
•Ausbau der Gleisanlagen für Steigerung des Bahnversands von
Fertigware per Bahn sowie für die Anieferung von Altpapier per Bahn.
•Niedrigere Emissionen durch Verlagerung von Straßentransporten per
LKW auf die Bahn
•Bessere Ausnutzung der Transportkapazitäten durch organisierte
Rundläufe über die Konzerneigene Speditionsgesellschaft Visurgis in
Hoya. Vermeidung von Leerfahrten.
37
Danke für Ihre Aufmerksamkeit!
Thank you for your attention!