Turning waste paper into reusable pulp

Nippon Paper wanted to relocate an existing de-inked pulp plant from Melbourne and reconstruct a modernised paper recycling plant at their Australian Paper Maryvale Mill.

There were three major elements to making this happen. Existing equipment needed to be relocated from Fairfield Mill, Melbourne. The plant needed to be modernised with a more functional layout and additional equipment from Japan. And the redesigned de-inked pulp plant, wetlap machine and baling line had to be reconstructed at Maryvale.

A key priority for Nippon Paper Group was to re-use the maximum amount of available materials when relocating the equipment, and equipment was used from both Fairfield Mill and Nippon Paper Industries in Japan. Finally, it needed interconnecting services.

Wood Beca (formerly Beca AMEC) supported this challenging project from feasibility through to implementation, providing project planning, scheduling support and detailed engineering design services.

During detailed design phase, the layout was reworked into a more efficient configuration while still maintaining the equipment’s correct orientation. To support Nippon Paper Group’s sustainability goals, the original process was modified to improve the quality of the recycled pulp the plant produces.

This means the new plant diverts over 80,000 tonnes a year of white waste paper from being exported or sent to landfill. Instead, it converts it into 50,000 metric tonnes of de-inked pulp which can then be used to manufacture recycled fine white paper.

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