The paper industry is undergoing a profound transformation, driven by high energy costs and the increasing focus on climate protection. While the objective of optimizing costs and improving process efficiency to remain competitive remains central, companies are placing more and more emphasis on sustainability and the development of innovative fiber-based products for diversified markets
In 2023, global production of carton and packaging paper exceeded 265 million tons, and forecasts indicate steady growth. However, meeting market demand is no longer enough: increasingly strict regulations and customer expectations regarding environmental performance are pushing manufacturers to review their processes in terms of energy efficiency and resource usage. Particular attention is given to high-consumption stages, such as dewatering, where vacuum systems can account for 20 to 25% of the total electricity consumption of a paper mill. In this scenario, optimizing energy use becomes a strategic lever both for environmental improvement and for economic efficiency.
Improving energy efficiency in paper production
Optimizing vacuum systems offers significant savings potential. An example is the Turbair system, developed by Everllence in Switzerland. Unlike traditional liquid ring pumps, which are subject to wear and performance losses over time, modern Turbair blowers are designed for stable and efficient operation. Thanks to the frictionless operating principle, they eliminate energy losses caused by water rings and consume up to 30% less than conventional systems. Another important feature of the technology is its ability to maintain high efficiency even under partial load conditions. This load flexibility enables additional energy savings of up to 35%. In conversion projects from conventional liquid ring pumps to Turbair technology, documented energy savings range between 40 and 60%.
By adapting vacuum levels to actual demand through frequency-controlled drives, operators can precisely adjust vacuum levels to production needs. This flexibility in vacuum management allows for additional energy savings of up to 20% and prevents avoidable energy losses caused by excessive system expansion. In some applications, further reductions of up to 20% can be achieved by optimizing process parameters.
Beyond energy efficiency, Turbair systems eliminate the need for sealing water, with benefits in operating costs, water consumption, and environmental impact. Another advantage is the possibility of residual heat recovery: exhaust air, with typical temperatures between 120 °C and 165 °C, can be utilized via heat exchangers, allowing for internal recovery and reuse of 70–80% of the input drive energy, for example for process water or building heating.
By combining these measures, the total energy consumption of vacuum systems in paper production can be reduced by up to 80% when replacing liquid ring pumps with high-efficiency Turbair blowers. In a context where efficiency and sustainability are crucial for competitiveness, modern vacuum technology proves to be a strategic lever for manufacturers aiming to reduce both operating costs and environmental impact.
Flexible vacuum blower solutions for the paper industry
Paper production processes require vacuum systems capable of adapting to a wide range of operating conditions. Everllence offers single-stage and multi-stage solutions, each optimized for specific process stages and performance requirements.
RT Single-Stage Blower
Airflow from 200 to 1,450 m³/min and vacuum levels up to 65 kPa. Automatic outlet adjustment allows the airflow to dynamically adapt to production variations, making the RT series particularly suitable for applications such as felt conditioning in tissue production, where conditions can vary significantly.
RC Multi-Stage Blower
Up to four suction nozzles and four separate vacuum levels. Airflow from 180 to 2,800 m³/min and vacuum levels up to 75 kPa. Designed for high-demand production environments, the RC series is ideal for the production of graphic paper, board, and pulp, where maintaining a stable vacuum is essential to ensuring process quality.
