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The custom design of Inox BF machinery for pulper treatment reduces energy and water usage costs, thanks to increased efficiency and a recirculation system
As long as the ecological transition remains primarily a matter of image, it seldom receives the necessary attention from companies to be fully realized. In the absence of regulations and deadlines, the only alternative path is innovation, which can transform a requirement into an opportunity.
For paper mills, this means focusing on an area that has only recently been explored due to a shift in awareness and, more importantly, because of the rising costs of energy and water. These factors, once minor in the production cycle, have now become priorities for both enhancing company image and optimizing costs. This shift offers a significant advantage to those who adopted this approach early on.
Graziano Frateschi, Legal Representative and Co-Founder of Inox BF, explains: “Our work focuses on a significant aspect of the ecological impact of paper mills: processing wastes. We manage pulper wastes; with our technologies, we significantly reduce both the amount of water and energy required, while also enhancing recycling.”
Founded in 1983, Inox BF has a forty-year history born from the collaboration of Bianchi and Frateschi, who were both operating in the same field but with different roles. Its primary goal has always been to develop effective solutions for issues related to the collection, washing, transport, and compaction of pulper wastes, as well as the filtration of machine circuit water and plant wastewater.
“In 1988, we made the most significant transition,” continues Graziano Frateschi. “At that time, we were primarily focused on maintenance, and the competition in our area was very high. We decided to shift directly to designing and manufacturing machines. We realized that the sector was becoming overcrowded, and someone had to step aside. Being among the first to make this decision soon proved to be an advantage.”
The transition was partial, keeping some of the original activities to support the gradual development of new purposes, which have now become the main focus. “Currently, maintenance is still included in the services offered by the Capannori company, but it is now limited to the systems we manufacture.”
“We focus on sustainability while also helping to reduce energy costs and, in particular, water usage. Our design office is capable of creating highly customized systems.”
Building customized solutions means achieving greater reductions in energy consumption and better control over maintenance costs. This is crucial for a company, as it impacts amortization times significantly. Additionally, it addresses the current need to optimize the ecological impact of waste disposal.
Inox BF solutions effectively reduce the weight and volume of pulper wastes while simultaneously recovering and reintroducing the extracted water into the production cycle. These technological solutions are crucial for lowering the water requirements in paper and cardboard production. This is largely achieved through the CONICDRUM, a machine used for washing and recovering fibers. Its large capacity allows it to handle wastes from Tetrapak processing as well.
The pulpers are first washed, then shredded, and finally compacted. In the final step, a dryer removes the remaining water, which is then directed to a recovery process. As a result, only a small, completely dry portion is sent to disposal.
This solution has been adopted by several major producers in Italy and is increasingly being used abroad as well. “Expanding the market was not just a choice but a necessity, as the Italian market alone was no longer sufficient. Our technology is well-regarded internationally, with clients now across Europe, North America, and increasingly in South America, a rapidly expanding market. Consequently, we are focusing on this region with the CONICDRUM machine sized 2400×10000 for processing Tetra Pak — a size previously not produced beyond 2200×10000.”
An important factor in our development comes directly from our clients. By maintaining constant communication and actively listening, we can understand their needs and direct our internal research activities accordingly. “The issue of energy consumption, in particular, was highlighted by some of our client paper mills. We addressed this concern and successfully developed machines with significantly reduced energy consumption, while also decreasing the amount of waste, which is often challenging to manage.”
Continuous innovation
The concept is simple: extracting as much water as possible from the pulper wastes reduces both the weight and cost of the discarded material. By optimizing materials and processes, energy requirements are also reduced. With the addition of water recirculation, the cycle is complete. Inox BF achieved this before others.
“On a compacting press, a medium-sized paper mill with a production of around 1,500 quintals can recoup the investment within five months. Considering an investment of around fifty thousand euros, this is certainly an interesting prospect.”
Adopting a dynamic approach is crucial for business success, especially in an industry where daily challenges are commonplace. The paper sector, in particular, cannot ignore the current unfavorable conditions. Alongside the long-term shifts in production geography, the industry is also facing the consequences of an unpredictable economic environment. “The sector is undoubtedly going through a sluggish period, but this doesn’t affect us. This is mainly because paper mills are investing in tools that help them save money and optimize processes—exactly what we specialize in, with the ability to deliver proven results.”
The packaging paper sector is currently facing challenges, whereas the production of kitchen and toilet paper remains steady. Although raw material supply issues were a significant concern for a time, these are now largely being resolved.
This issue is particularly significant for customers dealing with raw materials, as each order at Inox BF is treated as a standalone project, with timelines and costs calculated in real-time based on current conditions. “We operate on a per-project basis and do not maintain inventory. As a result, the costs quoted are subject to real-time fluctuations.”
Overall, the situation remains favorable for the company, thanks to a series of forward-thinking decisions and the ability to anticipate industry needs. “We look to the future with optimism,” says Graziano Frateschi. “We are developing further innovations, although it is still premature to discuss them. However, we will remain focused on improving wastewater treatment and the recovery of plastic parts from pulpers, which can be processed separately at a later stage.”
ECODRUM and CONICDRUM are among the most important machines in Inox BF’s product range, especially for pulper treatment. Both are designed to facilitate the removal of contaminants from the bottom of processing residues, streamline the discharge phases, address potential environmental contamination issues, reduce the volumes of water required for washing contaminants, and simplify the handling and transport of wastes to the subsequent compaction phase.
In particular, the ECODRUM is installed with an inclined shaft and a feed opening directly connected to the waste pits or collection channels of one or more pulpers. This setup enables simultaneous dewatering, contaminant washing, lifting, and transport, thereby facilitating the feeding of the compactors.
The CONICDRUM, on the other hand, is installed with a horizontal shaft and a feed opening directly connected to the bottom of the pulpers. Its conical shape enhances the volume of the drum and increases the retention time of the waste inside, allowing for thorough washing and consequently reducing fiber losses.