Carolin Bauer, Essity, Mainz-Kostheim

Tork PaperCircle® – Used towel paper as a new raw material for paper mills

The goal of recovering resources and eliminating materials that are simply lost in the product life cycle inspired Essity to develop the Tork PaperCircle.

In the washrooms, paper towels are collected separately in labelled containers, collected by a recycling partner, returned to Essity’s local plants and recycled into new hygiene products.

Without Tork PaperCircle recycling, towel paper ends up in residual waste and is then thermally incinerated. With Tork PaperCircle, this waste can be turned back into a new resource and the environmental impact of incineration can be reduced. In total, Tork PaperCircle helps to save 20 per cent of waste and reduce the overall carbon footprint by 40 per cent.

The service began as a pilot project in collaboration with customers and business partners. Today, it is an award-winning, sought-after service that is offered to customers in various European markets and is being further expanded. With the Tork PaperCircle service, Essity has also laid the legislative foundation at the European level for the recycling of towel paper, enabling other suppliers to introduce a similar process.

The speaker

Carolin Bauer is Customer Service Manager at Professional Hygiene and responsible for digital and sustainable services at Tork.
She has been with the company since 2018 and has been involved in the Tork PaperCircle division from the very beginning, responsible for the Tork PaperCircle service in various European countries.

Peter Biza, Yannick Rabot, Quentin Sanfeliu

Optimised control of organic contaminants – predictive lab test and industrial results

Detrimental contaminants are one of the major problems in board and paper machine circuits especially when recycled fibres are used as raw material. They can build up deposits on cylinders, felts and fabrics, disturb retention systems and the efficiency of other process additives. They also can impair the final paper or board quality e.g. building visible dirt spots or mechanical defects on the surface. Unwanted impurities have the potential to reduce the productivity as well as the quality of the final paper or board.

A wide variety of different lab tests are used to quantify the impurities and judge the efficiency of additives to control such substances. In this work, some methods will be presented that help to determine the level of impurities in water circuits but also to select the optimal additive to control or remove these impurities.

The presented methods focus on microparticles and colloidal or dissolved substances, a class of impurities that is very challenging to quantify and control with additives. Optical methods like the classical turbidity measurement were used to measure small, solid particles. The Chemical oxygen demand (COD) was used to quantify the organic substances in the water. Finally, a hydrophobic fluorescence dye and a flow cytometer were used to quantify small, hydrophobic particles that have the potential to build secondary stickies.

Adsorptive engineered mineral additives were used to remove the detrimental substances from the water or to control them by fixing them on the surface of natural minerals. Combining these methods will allow to select the optimal solution for contaminant control in board & paper mills. Using natural & engineered minerals helps reduce the chemical load in water circuits and makes the contaminant control sustainable for all kinds of paper and board.

The speaker

Peter Biza studied chemistry at Graz University and started his career in 1990 in Austria as a researcher for mechanical pulp and recycled fibres. In 1996 he joined the Naintsch Mineralwerke (today Imerys) as manager for pitch and stickies control. In his career, he was Senior market manager Paper Americas, laboratory manager, technical director paper and Innovation manager. In the last few years, he worked on projects for barrier applications, pulp bleaching, runnability improvement and moulded fibres. Peter is the author of numerous publications and patents.

Ralph Dittmann, Managing Director WKS Druckholding GmbH, Wassenberg

Print! For the sake of the environment!

On the impact and sustainability of printed and digital advertising.

Impact: Customers have long since made up their minds – they have become hybrid and expect both print and digital.
Sustainability: The carbon footprint of printed products from the perspective of one of Germany’s largest commercial printers compared with data from digital advertising.

And … What is the state of our forests? The connection with paper production?
All the data and facts used are taken from reputable, publicly accessible sources and not only allow a change of perspective but sometimes lead to a real “aha effect”.

The speaker

Dr Ralph Dittmann, born in Dortmund, studied mechanical engineering at RWTH Aachen University, where he obtained his doctorate in 1998, supported by a doctoral scholarship from the German Research Foundation in the research training group “Interdisciplinary Strategies for the Protection of the Environment”. His dissertation was dedicated to the topic of “high-quality recycling of fibre-reinforced thermoplastics”.

From 1997 to 1999, he was Head of the Car Body Division at the Institute of Automotive Engineering Aachen at RWTH Aachen University and at Forschungsgesellschaft Kraftfahrwesen mbH Aachen. He then moved to the Boston Consulting Group in Düsseldorf and worked as a management consultant. From 2001 to 2007, Dr Dittmann was head of the Production and Technology division at Mohn Media Mohndruck GmbH in Gütersloh, a Bertelsmann AG company.

Dr Dittmann has been Managing Director of the WKS Group since 2007 and was awarded the FUJIFILM Gold Award as Print Shop Manager of the Year in 2022. He is the author and co-author of numerous publications, including on the sustainability of print products.
*** Translated with www.DeepL.com/Translator (free version) ***

Axel Fischer, Chemist and science writer, INGEDE Public Relations

LED UV and other current developments in printing processes and deinkability

Everybody wants to save time and money, so printers try to speed up production – one technology is UV curing. But UV inks have historically been a major problem in the deinking process. This has changed, but there are still some inks that are not “state of the art”. Varying the energy of UV-LEDs shows interesting aspects. And digital printing tries to cut an increasing slice of the printing market, but especially inkjet (and derivatives) is not always the sustainable choice.

The results of recent deinkability tests will be presented and compared with INGEDE’s ample collection of results from the last two decades.

The speaker

Axel Fischer studied chemistry at Munich Technical University and worked there in the field of liquid-liquid extraction. After a science writing grant, he worked for newspapers and magazines, among others composing and presenting a science TV show for three years. Since 1994, he has been responsible for the public relations of INGEDE, now the International Association of the Paper Recycling Industry.

He represents INGEDE at international events and working groups dealing with recyclability, digital printing technologies, and sustainability and ecolabels in the paper chain. He gives presentations at international conferences and consults printers and OEMs on the recyclability of printed products.

Peter Görlitz, Sonoco Consumer Products GmbH

Paper composites in recycling – Findings and conclusions on the composite can (wrapping can)

Composite cans are a type of rigid paper packaging used for food contact, among other things. They are available in different material compositions and with different components. The core is predominantly made from recycled paper and is ideally returned to paper recycling. Coatings applied to the inside are used when the product demands the barrier properties of the packaging.

The recyclability of this type of packaging is often questioned. For this reason, Sonoco and its partners decided to systematically investigate this and trace the life cycle of the packaging from the time of disposal through collection, sorting, defibration and production of recycled paper. While the collection process looked at how the packaging behaves when exposed to moisture and pressure, the sorting process focussed on the individual sorting steps and the factors influencing the packaging materials used on the sorting result. During defibration, the behaviour of the paper body was measured on a laboratory scale and qualitative statements were made about the foreign substances. Building on this, larger quantities were pulped and analysed in semi-industrial pulpers and in real paper mills. Statements on the behaviour can be made here primarily by looking at the spit substances.

The external factors in the collection mean that the composite can arrives at the sorting process as a flat object. There, the sorting steps of conveying on the belt, magnet, eddy current separator, IR beverage cartons and IR PPK from LVP were analysed. The possibility of adapting the detection routine and the associated change in bale quality was successfully tested with two equipment manufacturers, as was the use of modern detection methods, which detect the composite cans exceptionally well after a training phase. Furthermore, the packaging was defibrated on a laboratory scale with different observations in the hand sheets caused by the choice of coating. The compatibility of the composite can with the processes was demonstrated in external projects focussing on innovative defibration technologies and final cleaning stages. In large-scale trials with several tonnes of sample material or production rejects the topic of defibration was approached step by step. Initially, for example, the material was pulped in thick pulpers, and in a subsequent step, this was also carried out in the material mix in conventional pulpers. Finally, it was shown that exposure to the test material for several weeks has no effect on the water cycle in the paper mill.

To summarise, it was shown that the technical recyclability of the packaging type is a given and can be positively influenced by the choice of materials used. In other words, this means that feedback from the recycling chain is decisive for the packaging manufacturer’s development decisions. Despite the positive results, there is resistance to paper recycling of coated paper packaging. As this cannot be explained by technical incompatibility, it is necessary to discuss open-endedly what experiences other market participants have had, and what other influencing factors prevent the acceptance and recognition of recycling, and how this situation can be improved in the interests of all.

The speaker

Peter Görlitz, Sustainability Manager at Sonoco, harmonises the packaging design at Sonoco with legal requirements and the requirements of external stakeholders. This includes recycling tests, collaboration with technology providers and participation in trade associations. He integrates sustainability tools into Sonoco’s processes and sets targets for the strategic direction of the European business.

Felix Hake, Senior Data Scientist, Consultingtalents AG, Walldorf, and
Hanna Schwandt, LEIPA Group, Schwedt

Data, data, data – Step by step to an assistance system for the paper industry with AI, analytics and expertise!

The BMWK-funded KIBAPap project “AI-based operator assistance system in the paper material cycle” optimises paper production using the MADDOX4Paper assistance system. KIBAPap is supported by the LEIPA Group, Consultingtalents AG, Munich University of Applied Sciences, IPEM (University of Siegen), VEOLIA, Fraunhofer IVV and PROPAKMA. LEIPA converts over 1.5 million tonnes of waste paper into high-quality paper and packaging solutions every year. Consultingtalents AG uses innovative SAP solutions as well as analytics and AI applications to optimise business and production processes in the manufacturing industry for flat materials.

MADDOX4Paper is a system from the paper industry for the paper industry and consists of the two modules operator assistance MADDOX and expert assistance DIVE. The system monitors production processes, recognises quality problems at an early stage, quickly identifies deviations from optimum machine operation and generates forecasts. Information is then issued to the machine operator as appropriate to the situation and knowledge is made available across departments.

MADDOX addresses the following challenges in the industry: shortage of skilled labour, complex problem solving and knowledge sharing. It was introduced at LEIPA in Schwedt at PM5 last year. Knowledge is made available across all shifts via various knowledge cards that have now been created and displayed as required.

DIVE creates transparency in production and business processes through the use of modern AI and analytics tools.  For example, AI tools are used to create soft sensors and provide information on possible causes of errors. The Golden Run focusses on the automated display of deviations from optimal machine runs. Possible causes of errors are prioritised and made available from several hundred process parameters.

The gradual expansion of MADDOX4Paper with positive feedback from the production team shows the success of the close collaboration between humans, AI and analytics.

The speaker

As a data scientist, Felix Hake works on the analysis, visualisation and modelling of complex dynamic systems. He focuses on the development, critical evaluation and implementation of algorithms and mathematical models using modern AI tools.  As a data scientist at Consultingtalents AG, he works in a passionate team of consultants and software developers working on digitalisation in the paper industry. Consultingtalents AG is the joint coordinator of the KIBAPap research project, which aims to increase efficiency in the paper recycling cycle through digitalisation and the use of AI.

Felix Hake’s tasks within the project include selecting relevant influencing factors from several thousand machine parameters, analysing them and developing the forecasting module. To this end, ongoing workshops are held with experts from the industry to record the highly complex underlying relationships in terms of data technology. This demonstrates the potential of AI to the machine operators, continuously improves the accuracy of the model and ensures that the operator assistance system can be utilised.

Karsten Hunger, Managing Director of the Paper and Film Packaging Industry Association (IPV), Frankfurt (Main)

Paper and plastic – a fabulous combination with a future?

Paper belongs into the paper recycling bin, plastic into the yellow bin – the (packaging) world is actually quite simple. But for some years now, cherished certainties have been called into question. What is actually paper? What is plastic? And where do fibre-based composites belong? These questions are not only on the minds of recognised packaging experts, but now also on the minds of some consumers.

Unfortunately, simple populist statements do not help in this context. Neither ‘Why fibre-based packaging is bad for recycling’ nor ‘What is plastic and why is it harmful’ attempt to reflect the complexity of the current issue.

We embark on a fairytale journey into a complicated regulatory world in which packaging licensing (perhaps) has the power to change entire industries. In which the contents of paper bins are assessed either legally or in real terms. And in which all European countries will speak the same language in the future – at least for some symbols.

Will it remain a fairy tale or will the big ideas become reality?

The packaging world is facing major changes. The European Packaging Regulation (PPWR) is in the starting blocks, but despite several hundred pages of text, so much is still unclear. At the same time, all member states are vying for influence and the greatest possible freedom in interpreting the text. We dare to take a look into the future and at the same time face up to some of today’s challenges for packaging made of paper, plastic and, of course, their composites.

Karsten Hunger is

  • 40 years old
  • since 2017 Managing Director of the Industrieverband Papier- und Folienverpackungen e.V. (IPV, flexible packaging), Managing Director of the Fachvereinigung Hartpapierwaren und Rundgefäße e.V. (FHR, winding cores) and the Gemeinschaft Papiersackindustrie e.V. (GemPSI, paper sacks)
  • also General Secretary of the European Core and Tube Association (ECTA, winding cores)
  • graduate of the Dual study programme in electrical engineering at the Zittau/Görlitz University of Applied Sciences
  • Work for various companies in the electrical industry
  • 2017 Change from standardisation manager at the VDE Association for Electrical, Electronic & Information Technologies to the packaging industry
  • since then, supporting member companies in all areas of regulation
  • at Linkedin

Dipl.-Chem. Antje Kersten, Technische Universität Darmstadt, FG Papierfabrikation und Mechan. Verfahrenstechnik

PFAS in paper for recycling: risks for recycling and the environment? 

Due to their chemical and physical properties, perfluorinated and polyfluorinated alkyl compounds (PFAS) have been widely used both as process chemicals and as functional additives in the manufacture of consumer and industrial products. These substances have also been used in the production and functionalization of papers and are still legally used, albeit in decreasing quantities. Due to their strong binding to the fibres and their persistence, PFAS are contained in the recycling paper cycle and can also be detected in recycled paper.

Due to their (eco)toxicological effects, the use of PFAS for industrial and household applications is being increasingly restricted. Determination methods for PFAS (individual substances and sum parameters) and limit values for maximum permissible concentrations have now been defined for various environmental media and food contact applications. With the adoption of the PPWR, this topic has also come into focus for fibre-based packaging.

How critical is PFAS contamination in the paper recycling cycle? What environmental impacts are to be expected in paper mills processing paper for recycling? In this lecture, the first results of the project “Determination of an input and output balance for per- and polyfluorinated alkyl substances in paper for recycling processing paper mills” of the Federal Environment Agency (FKZ 3722 36 302 1) will be presented and discussed.

The speaker

Antje Kersten studied chemistry at Martin Luther University Halle-Wittenberg, specialising in analytics and environmental chemistry. After graduating in 1994, she worked as a research assistant, including at the Institut für Lacke und Farben e.V. in Magdeburg. She joined the Department of Paper Technology and Mechanical Process Engineering at TU Darmstadt in 2004, specialising in environmental issues in the paper industry, ingredients in paper and board, paper chemistry and food conformity. Antje Kersten is also head of the department’s chemistry laboratory. She is a member of various working groups and committees. Among other things, she works in the “Paper” committee of the BfR Commission for Consumer Goods, is a member of the Zellcheming Technical Committees for Environmental Issues (ENVI) and Chemical Additives (CHAD), and various working groups of the German Paper Industry Association.

Tamas Kordsachia, Steinbeis Papier, Glückstadt

NIR Macrosticky Determination According to DIN SPEC 6745 in the Production of Graphic Recycled Paperr

The presentation explores the use of NIR Macro-Sticky Determination (DIN-Spec 6745) in graphic recycled paper production as an alternative to Ingede Method 4. It compares both methods, their correlation, and suitability for process control. While NIR offers efficiency, limitations remain. Collaboration in adhesive design and recyclability assessment is key to optimizing recycling.

The speaker

MSc in Wood Science at the University of Hamburg
Since 2017 Process and Recycled Paper Technologist at Steinbeis Papier
Since 2024 Head of Quality Laboratory

Ulrich Leberle, Raw Materials Director, Cepi

The Revised EU Regulation on Packaging and Packaging Waste and the impacts on paper recycling

The revised PPWR has been adopted at the end of 2024 and is published in the Official Journal of the EU. It has entered into force 20 days later and will be applicable from 12 August 2026. Many provisions have separate timelines. Several pieces of secondary legislation will have to be developed and adopted. Some of them affect directly the way paper packaging products are designed, collected and recycled.

There will be an implementing act on harmonised labelling requirements for packaging. The objective is to have one label with sorting instructions for the consumer matching the sorting systems in all the member states. A label for paper, for board and for beverage cartons seems to be set, but what about other fibre-based composites? The Joint Research Centre of the European Commission is preparing proposals with the help of an expert group and targeted consultations. Fibre Packaging Europe is positioning on the issue as a whole value chain. The first proposals are expected in March.

There will be a delegated act on Design for Recycling Criteria. By 2030 all packaging will have to comply with Design for Recycling Criteria and only performance grades A, B, and C will be allowed on the market. The PPWR obliged the Commission to consider standards and has requested CEN to work on proposals. This intensive process has started and is expected to deliver tangible results by the end of the year in the form of at least a draft CEN deliverable. Many from the paper industry are heavily involved in the process and are building on valid work on fibre-based packaging recyclability in Cepi and 4evergreen over the recent years.

The Cepi recyclability laboratory test method and the only recently published 4evergreen recyclability evaluation protocol include valuable information for these processes. Cepi is confident that definitions, concepts, and positions developed in the sector to reach higher recycling rates will help match the requirements of the PPWR.

The speaker

Ulrich Leberle was born in 1975 in Nördlingen, Germany. He holds Master degrees in history from the Universities of Tübingen (Germany) and Aix-en-Provence (France).

After professional experiences in the European Commission, the European Parliament and as a consultant in a Brussels-based company specialising in EU Public Affairs, he joined the Confederation of European Paper Industries (Cepi) in November 2005. Having held several positions in the area of raw materials at Cepi, his responsibilities in his current role of Raw Materials Director include the availability of raw material both from forestry and recycling and the policies impacting them.

Stefan Lübsen, Managing Director of INGEDE, Bietigheim Bissingen

Is white consumer packaging suitable to increase the availability of deinking grades on the market for paper for recycling?

Various white consumer packaging was analysed in terms of deinkability and compared with different blends of grade 1.11. Sortability in recovered paper sorting plants was discussed with plant operators and approaches were formulated.

To assess the potential of white consumer packaging on the market for deinked grades, the European market for paper for recycling is first analysed. What routes does this packaging take in the paper recycling cycle?

Various blends of white consumer packaging were tested for deinkability in the laboratory and compared with different mono-fractions (newspapers, magazines, office paper) and blends of grade 1.11 with varying proportions of brown fibres.

Various sorting strategies for this packaging were discussed with operators of recovered paper sorting plants.

The speaker

Stefan Lübsen learned as a papermaker and then studied process engineering, specialising in paper production, at the Munich University of Applied Sciences. He gained many years of experience in various paper mills and has in-depth knowledge of the production of packaging and graphic papers. Mr Lübsen has been working at PROPAKMA since last year and was entrusted with the management of INGEDE in January 2025.

Ulrich Neumüller, Repulping Technology, Schiltberg 

Bessere Trennung und Rückgewinnung von Rohstoffen mit Kavitation – Erfahrungen aus einem autarken Recyclingwerk für Verbundverpackungen

Das neue Zerfaserungsverfahren mit dem Kavitationsstofflöser bietet eine zukunftsweisende Möglichkeit zur effizienten Aufbereitung von Abfallmaterialien. Besonders hervorzuheben ist die Flexibilität des Verfahrens, das sowohl autark als auch integral in bestehende Altpapierprozess integriert werden kann. Durch den gezielten Einsatz von Kavitationsenergie werden Materialien auf molekularer Ebene bearbeitet, was zu einer verbesserten Trennung und Rückgewinnung von Rohstoffen führt. Die autarke Funktionsweise des Verfahrens senkt die Betriebskosten, während die hohe Effizienz zu einer signifikanten Steigerung der Rentabilität führt. Zudem ermöglicht das Verfahren eine modulare Skalierbarkeit, die es den Anwendern erlaubt, es an verschiedene industrielle Anforderungen anzupassen und somit einen nachhaltigen wirtschaftlichen Vorteil zu erzielen.

Die ersten Projekterfahrungen aus dem Pilotprojekt zeigen, dass das Kavitationsverfahren in der Praxis große Potenziale bietet. Zu Beginn waren vor allem technische Anpassungen notwendig, um die Materialausbeute zu optimieren. Eine kontinuierliche Anpassung der Parameter führten zu einer signifikanten Verbesserung der Recyclingrate und einer Reduktion von Energieverbrauch und Abfall. Auf Grundlage dieser ersten Erfahrungen werden nun weitere Optimierungen vorgenommen, um die Prozessstabilität und -effizienz weiter zu steigern, mit dem Ziel, das Verfahren auch für größere industrielle Anwendungen zu skalieren.

Das Verfahren eignet sich besonders für die Recycling von verschiedenen Altpapiersorten, insbesondere für solche, die bisher schwer recycelbar waren. Dazu zählen stark krafthaltige und nassfeste, als auch beschichtete Papiere in der Kombinationen von Papier/Kunststoff oder metallisierte Papiere, die mit traditionellen Verfahren nur unzureichend zerfasert werden können. Die Kavitationsbehandlung ermöglicht eine schonende, aber effektive Trennung der Papierfasern von Verunreinigungen und Beschichtungen. Dadurch können qualitativ hochwertige Rezyklate gewonnen werden, die in der Papierindustrie wiederverwendet werden können, was die Kreislaufwirtschaft stärkt und die Notwendigkeit für den Einsatz von Primärrohstoffen verringert.

Zur Person

Ulrich Neumüller, Gründer der Repulping Technology, verfügt über umfangreiche Erfahrung in der Unternehmensberatung, der Restrukturierung von Industriebetrieben und dem Projektmanagement. Nach zahlreichen Projekten in der Papierindustrie gründete er die Repulping Technology, mit dem Ziel, das Faserstoffrecycling sowohl effizienter als auch qualitativ hochwertiger zu gestalten. Nach der erfolgreichen Entwicklung des „Kavitationsstofflösers“ wurde in Österreich die erste industrielle Anlage als Turnkey-Projekt für einen Kunden realisiert. Darüber hinaus war Herr Neumüller viele Jahre lang Mitglied und Vorsitzender des nationalen ISO 55000 Komitees für Asset Management.

Olaf Postel, PreZero Service Deutschland GmbH & Co. KG, Porta Westfalica

Redesign your value chain – solutions for individual material cycle

What does PreZero.rechain® do?
PreZero.rechain® is one of PreZero Germany’s full-service consulting programmes. The aim is to support manufacturers in the implementation of sustainable recycling concepts for products and packaging so that they are not treated as waste at the end of their life or use, but are recycled and reused as recyclable materials – in line with the motto: REdesign your value CHAIN.

As the process of a company’s value chain usually follows the linear pattern of ‘buy, make, sell’, we break it down or expand it. This conceptual rethink enables circular value creation. With individualised take-back systems for individual products and product packaging, we promote raw material cycles: secondary raw materials are obtained through processing and recycling, which are then used again for the production of new products or packaging. In the best case scenario, this results in a ‘closed loop’ and the manufacturer can reuse its own product or product packaging as recycled raw materials in its own value chain.

Every product cycle is unique and so are the conditions on site. This may concern the material properties of the specific product, but also manufacturing methods, logistics processes, site infrastructures and much more. We support manufacturers on their path to more sustainable business practices and develop an individually tailored system based on your circumstances with our three-phase programme.

The speaker

Olaf Postel at Linkedin
Academic titles: Diplom-Kaufmann; Master of Strategic Leadership Towards Sustainability
In the waste disposal and recycling industry since 2011, industry experience

Dr.-Ing. Karoline Raulf, Department of Anthropogenic Material Cycles, RWTH Aachen University

The EnEWA project: three years of intensive research – and now?

A team of researchers, papermakers and processing engineers spent more than three years researching the use of paper made from lightweight packaging (LVP) in paper production. The technical feasibility was very successfully demonstrated on an industrial scale and a marketable product was created. The presentation summarises the successes but also highlights the final hurdles that need to be overcome along the process chain to make widespread use of PPK made from LDPE in the future.

The speaker

Education:
2003–2009: Studying Waste Management Engineering, RWTH Aachen University
2016: Doctorate (Dr.-Ing.), RWTH Aachen University

Career:
2020 bis heute: Akademische Rätin, Institut für Anthropogene Stoffkreisläufe der RWTH Aachen, Prof. Dr. Kathrin Greiff
2016–2020: Post-Doc (wissenschaftliche Mitarbeiterin), Institut für Aufbereitung und Recycling der RWTH Aachen, Prof. Dr.-Ing. Thomas Pretz 
2015–2017: wissenschaftliche Mitarbeiterin in Teilzeit, Institut für Metallurgische Prozesstechnik und Metallrecycling der RWTH Aachen, RWTH-Büro des KIC Raw Materials, Prof. Dr. Ing. Dr. h.c. Bernd Friedrich
2009-2016: Doktorandin (wissenschaftliche Mitarbeiterin), Institut für Aufbereitung und Recycling, RWTH-Aachen, Prof. Dr.-Ing. Thomas Pretz

Thomas Römbke, AVG Ressourcen GmbH, Cologne

Digitisation in sorting paper for recycling to optimise the deinking fraction

The latest developments in camera-based object recognition and agent-controlled impurity analysis in paper processing: how modern technologies can continuously monitor and improve the quality of sorting. Measuring points already implemented in the Cologne plant and the findings to date from real-time data analysis will be explained and provide a comprehensive picture of the current process landscape.

A particular focus will be on the optimisation possibilities that can be achieved by using artificial intelligence and automated feedback loops. The continuous adaptation and further development of these systems plays a central role in increasing the efficiency of sorting processes. Challenges associated with the implementation of such technologies are also discussed, particularly with regard to systematic errors and the standardisation of analysis procedures.

Finally, an outlook is given on the goals for 2025. These include the complete integration of control feedback into the PLC, improved coordination with NIR technology and data-based optimisation of production planning. The approaches presented should not only further increase the quality and efficiency of sorting, but also make an important contribution to resource conservation and sustainability in paper processing.

The speaker

Thomas Römbke is 54 years old, Head of Paper Processing at AVG, and has a total of 25 years experience with deinking sorting systems. Currently undergoing further training in “Python and visualisation”.

Sven Sängerlaub, Jonas Rittler, Jürgen Belle, Munich University of Applied Sciences, Sustainable Materials and Product Design and Biofibers and Paper

The impact of residual quantities of milk on beverage carton recycling

Residual quantities in packaging are not only annoying for consumers but also cause recycling challenges. In particular, Problems are expected with fibre-based packaging, because fibres are dissolved and processed during recycling using aqueous processes. The promotion of microbial growth is obvious.

An empirical study from our student has shown that up to 10 wt.% of filling goods remain in plastic packaging, particularly in the case of highly viscous products such as toothpaste. In the worst case, up to half of a sorting fraction can consist of residual quantities. There have been hardly any empirical studies on residues of beverage carton packaging for recycling. For our recent study, the residual quantities of milk in hundreds of 1-litre milk cartons packs were measured.

The distribution of the remaining quantities can be described using a log-normal distribution. Packs with larger residual quantities are therefore disproportionately included in the total residual quantity. Correlations of the residual quantities with the manufacturers of the packaging and the fat content of the milk or cream could not be identified. It is possible that the residual quantities were too widely scattered. Regional differences were found. Packs from the Czech Republic contained an average of 1.18 wt.% and therefore more residual quantity, packs from Germany 0.66 wt.% and from Austria 0.55 wt.%. On average, 0.66 wt.% residual quantity was measured in the packs. These values appear small. However, “with a mean value for the packaging weight with residual quantity of 35.8 g for 1-liter packs (some packs without closures), and 29.2 g without residual quantity, this results in a packaging material content of 81 wt.% for recycling.“

The Munich University of Applied Sciences, Department of Biofibres and Paper, is conducting research into recycling processes of fibre-based packaging. The specific effects of these residual quantities are to be investigated in more detail in future. Our results are a good basis for realistic investigations.

Results have been submitted in the journal BioResources and are currently under peer review.

The speaker

Sven Sängerlaub (ResearchGate) studied packaging technology at the HTWK Leipzig. In 2004, he began his scientific career at the Fraunhofer Institute for Process Engineering and Packaging IVV in Freising. There, he completed his doctorate on moisture-regulating films. He held various positions there as a scientist of the department Materials Development and he was business unit manager for packaging. He managed and acquired national and international projects as well as various bilateral projects with companies.

His expertise lies in the research areas of active, smart, functional, and sustainable packaging as well as barrier and biopolymers. He has broad project experience in these areas.

In 2019, he was appointed Professor of Packaging Technology at Munich University of Applied Sciences.

He was elected Chairman of the Executive Board of the bdvi.

Dominik Stumm, Woellner GmbH

Biologically clean: Sustainable stabilisation of deinking systems with probiotic bacteria

Recovered paper processing stock preparation plants in the paper industry are operated very differently depending on the raw material input. A particular challenge is the stable operation of deinking plants with the deinking and bleaching additives used.

Traditionally, these plants have been treated with biocides and biodispersants in order to keep the microbiologically induced problems, which are usually caused by biofilms, under control.

In recent years, the approach of biological cleaning with probiotic bacteria has emerged into a promising alternative to the biocidal, antimicrobial treatment of industrial water circuits in the paper industry. Environmental considerations, sustainability, user-friendly functionality and safety take centre stage.

In addition to improving operational hygiene in production processes, the probiotic microorganisms in Waropure® have shown surprising metabolic properties with regard to catalase formation in our own laboratory tests.

Catalase is one of the main reasons of the increased consumption of the bleaching chemical hydrogen peroxide. For decades, the biocide Glutaral or, alternatively, modern oxidative systems have been used for catalase control.

Together with our partner from the graphic paper production industry, we have been able to establish the probiotic treatment concept in deinking plants and the plant has been biocide-free for more than 4 years.

The speaker

Dominik Stumm studied chemistry at the TU Darmstadt and completed his doctorate there at the Ernst Berl Institute for Technical and Macromolecular Chemistry. From 2007 to 2009, he was a project manager at the Papiertechnische Stiftung in Munich, where he led various research projects on the optimisation and mode of action of chemical additives in the wet end. Between 2010 and 2016, he worked on the technical implementation of functional additives at BK Giulini GmbH and, from February 2015, at Kurita Europe GmbH, which acquired the business unit. From 2017 to 2019, he was Head of Paper Application Technology at Kurita Europe in Ludwigshafen.

Since 2019, he has been the R&D Manager of the Paper and Water Treatment business unit at Wöllner GmbH (PEC) and is responsible for the corresponding product portfolio (process additives such as deinking additives, retention agents, defoamers, cleaners, etc.).

Axel Subklew, Sprecher der Initiative “Mülltrennung wirkt”, Köln

And – where do I put the paper packaging? Waste separation, recyclability, labelling – what does the consumer do and what not?

The correct waste separation of fibre-based packaging is often a challenge. Coatings or material mixtures are often used, especially for food-safe packaging, to make it resistant to moisture or grease. However, these coatings make it difficult to allocate them to the correct recycling streams, such as waste paper collection or the yellow bin. This not only leads to confusion but also increases the risk of incorrect disposal, which disrupts the recycling process. How can we solve the problem of correct allocation to the correct recycling stream, yellow bin or blue bin?

The speaker

Axel Subklew has been the spokesperson for the “Waste Separation Works” initiative since 2020. He studied business administration at RWTH Aachen University and graduated with a degree in business administration. From 1997 to 2006, he worked for Duales System Deutschland as a country officer and group leader for the central region. He then moved to the Reclay Group, where he was responsible for waste disposal as Regional Manager until 2020. In this position, he was responsible for tendering and purchasing collection services, as well as organising information events and training courses on the topic of recycling.

Dipl.-Ing. Christian Trieb, PROPAKMA, Bietigheim-Bissingen
and Marie Geißler, PTS, Heidenau

On the test stand: How can you evaluate the recyclability of paper-based packaging?

The INGEDE Methods for analysing and the EPRC Scorecards for assessing the recyclability of graphic products are well developed and recognised. But what about the assessment of packaging? A lot has happened since this topic was first discussed at the INGEDE Symposium 2019, and exciting developments have been reported on at the INGEDE Symposium every year since then.

This year, too, there are many innovations to report. Two new laboratory methods can now be used not only to simulate recyclability in conventional stock preparation on a laboratory scale but also to investigate how packaging behaves in a flotation deinking plant or in stock preparation for speciality paper (beverage cartons). With the associated publication of the ‘Fibre-Based Packaging Recyclability Evaluation Protocol Version 1, January 2025’, these results can also be evaluated and classified.

At the symposium, you will learn why we need several laboratory methods and how the evaluation criteria differ. A brief outlook will show which core topics will need to be further developed and addressed in the future.

The speakers

Berufliche Laufbahn:
Seit 2016 Projektingenieur PROPAKMA GmbH, Geschäftsstelle INGEDE e.V.
2013-2015 Projektingenieur PTC GmbH, Geschäftsstelle INGEDE e.V.
2012-2013 Wissenschaftlicher Mitarbeiter Institution for Paper Science and Technology

Ausbildung:
Diplom Ingenieur Maschinenbau Studienrichtung Papier- und Chemieingenieurwesen, TU-Darmstadt (2012)

Relevante Arbeitsgebiete für die Normenarbeit:
Seit 2024 Technischer Berater für 4evergreen, Themenschwerpunkt Methodenentwicklung, Rezyklierbarkeit von Verpackungen und deren Bewertung
Seit 2022 Mitarbeit bei 4evergreen, Themenschwerpunkt Methodenentwicklung, Rezyklierbarkeit von Verpackungen und deren Bewertung
Seit 2022 Mitarbeit bei der CEPI Recyclability Test Methods Group
Seit 2022 Vorbereitungen innerhalb der PROPAKMA GmbH zur Einreichung der Überarbeitung der ISO 4046
Seit 2021 Leiter der Task Force Methoden bei der INGEDE

Academic qualifications
2017–2019 Master of Science in Waste Management and Contaminated Sites, Dresden University of Technology (TUD).
2014–2017 Bachelor of Science in Hydro Sciences, Dresden University of Technology (TUD).

Professional positions held
2019–present Project member at Papiertechnische Stiftung.

Present research/professional speciality
Main areas of focus include the evaluation of the recyclability of paper-based products within the scope of customer projects, test assignments and various research projects, as well as the consideration of the paper cycle from the point of view of recycling.
I´m also involved in the 4Evergreen initiative and in the extensive design and implementation of an increasing number of English and German online workshops on recycling and recovered paper offered by PTS.
• Method development mainly for recyclability test methods of fibre-based packaging
• Support and work within the initiative 4evergreen as technical advisor (WS1 & WS2) and Samplehub
• Support in committees like the DIN; INGEDE or VsKE
• Working within EU and German projects focusing on the recyclability of new developments and circular economy
• Costumer Consulting regarding Recyclability and Design for Recycling for paper-based packaging
• Performance of Recyclability Workshops for Costumers
• Performance of Laboratory Trainings for Customers on Recyclability Test Methods

Dr. Alexey Vishtal, Mayr-Melnhof Board & Paper

Challenges in recycling of barrier-fibre based packaging and opportunities for plastic replacement

Fibre-based packaging has great potential to substitute both flexible and rigid plastic packaging. This potential is largely based on the sentiment that paper and board have a high recycling rate and widely available recycling infrastructure. However, paper lacks barrier and other functionalities such as heat sealability, these have to be brought by thin polymeric coatings or lamination. Otherwise, plastic replacement would be just limited to applications where fibre-based packaging plays a structural but not functional role. This presentation will review the potential of plastic substitution with fibre-based packaging despite PPWR and other legislative tailwinds. Furthermore, it will highlight the major challenges in recycling of barrier fibre-based packaging.

The speaker

Dr. Alexey Vishtal is working at Mayr-Melnhof Board & Paper as a Head of Novel Packaging Development where he focuses on the development of novel fibre-based packaging with barrier functionality to offer a viable alternative for difficult-to-recycle polymer multilayer packaging. Before joining MM in early 2022, he spent seven years with Nestlé where he led fibre-based packaging development in their research organization. Before that, he held various positions in paper and related industries. Alexey has a paper engineering background and a doctoral degree in paper physics and converting.

Stefan Wessel, Landbell AG für Rückhol-Systeme, Mainz

Are the control elements set correctly? The LANDBELL dual system’s view of composite packaging and other fibre sources

Interaction of service packaging, beverage cartons/liquid cartons, blue bin contents and composite packaging from the yellow bag

Dual systems and the paper industry should not be seen as being in conflict or incompatible with each other, but rather as one of the possible keys to unlocking known and partially related fibre sources from household collection.

In view of the high volume of waste paper imported into Germany, the common goal must be to overcome prohibitions on thinking, the previously unspeakable and conflicting opinions in order to open up new opportunities within Germany.

As the leading dual system for paper packaging, the LANDBELL Group has a vital interest in tailoring the secondary raw materials available to it to the needs of the paper industry in the best possible way.

However, not only AFTER the waste has accumulated, but long before. This requires a provocative examination of the 95/5 rule, the relationship between composite packaging and beverage/liquid cartons and an intellectual and practical examination of the possible re-sorting of these qualities in a PPK sorting plant.

Furthermore, the overall view of the topic includes analysing the actual proportion of composite packaging in the PPK collection (blue bin) in a sober manner and using the findings profitably.

The speaker

1997–2004        Commercial training and study of Catholic theology in preparation for the ministry, Münster
2004–2010        Sales/key accounting Commercial waste disposal STENAU Städtereinigung GmbH, Nordhorn
2010–2016        Managing Director STENAU Städtereinigung GmbH, Nordhorn
2017–today       self-employed (quartz sand extraction), Haltern am See
2017–2019        Regional Manager South-West / Authorised Representative MAD Recycling GmbH (LEIPA Group GmbH), Munich and Ingolstadt
2020–today       Regional Manager North LANDBELL Deutschland GmbH, Mainz and Münster
2023–today       Authorised signatory / Head of Marketing and Recycling PPK in DACH LANDBELL AG für Rückholsysteme (LANDBELL Group), Mainz and Münster

Dr. Johannes Zipfel, MD Delsci GmbH

The paper revolution: Highly effective barriers against water – and still recyclable?

Paper is increasingly being established as a promising packaging material that fulfils the growing demands for sustainability and environmental compatibility. Its high recycling rate and availability based on renewable resources make it a key component in the development of sustainable packaging solutions. The challenge is to optimise the functional properties of paper, particularly concerning barriers against water, oxygen and grease, so that they meet the market requirements without compromising recyclability.

An apparent contradiction arises from the need to integrate highly effective barriers and at the same time ensure the recyclability of the material. This conflict of objectives can be addressed by the concept of “design for recycling”. The application of 4evergreen’s current evaluation protocol for recycling mills with a conventional process using the current Cepi recycling laboratory method as a development tool makes it possible to specifically analyse the interactions of barriers in the recycling process. This involves analysing at which point in the process chain the barrier can be removed in order to reduce undesirable effects such as the formation of stickies or sheet adhesion. Through the targeted use of suitable materials and an optimised design, the barrier can be efficiently removed to a large extent early on in the recycling process, for example during coarse screening.

This new class of material is still in the early stages of development and poses numerous challenges, particularly concerning the implementation of the requirements of the Packaging and Packaging Waste Regulation (PPWR). However, these challenges can be solved through targeted material development and process optimisation. Close collaboration between material developers and recycling experts is of key importance to successfully establish sustainable and recyclable next-generation packaging solutions.

The speaker

Dr. Johannes Zipfel studied chemistry with a focus on physical & macromolecular chemistry, followed by PhD studies at the Faculty of Macromolecular Chemistry (Marie Curie Fellow of the European Commission and 3-year stay at the Institut Laue-Langevin in Grenoble, France).
He started his industry career at Henkel as R&D manager for new ingredients in adhesives, beauty care, detergents and cleaners.

After positions responsible for the development of dishwashing detergents and Products like Persil, Somat, Pril and other brands, leading R&D positions for Henkel in Vienna, Düsseldorf, and Amsterdam, Head of Global Quality Management, and Global Supply Chain, in 2019 he became responsible for setting up DELSCI GmbH as an exclusive research facility for delfortgroup AG in Traun (Austria).  

As Managing Director Managing Director he is now responsible for all business, strategy and research issues of DELSCI GmbH as well as for building a unique business model to support customers in the transition from plastic to paper for sustainable packaging solutions.

From 2024 until the beginning of 2025, he was the Co-Lead for WS1 recyclability evaluation protocol within the 4EG initiative.

*** Most abstracts have been translated with the help of www.DeepL.com/Translator (free version) ***

Theme: Illdy. © Copyright INGEDE 2024. All Rights Reserved. All pictures copyrighted.