DS Smith recently completed the installation of new steam recycling technology that will reduce energy consumption by 20% in its Columbia, S.C. corrugated packaging facility. This investment is part of DS Smith’s sustainability commitments to its North American customers.
The new multi-million-dollar Baviera Steam Systems technology installed at the specialty coated box manufacturing plant efficiently recovers condensate typically lost in the corrugating process. Energy savings created through condensate recovery reduces DS Smith’s carbon footprint in Columbia, and the new technology also increases productivity by reducing maintenance downtime at the plant.
“Our South Carolina facility makes water-resistant, fully recyclable Greencoat® boxes for fresh poultry and produce providers – agribusinesses that recognize decarbonization as a key factor to their continued success,” said Steven Rose, Managing Director – Packaging, DS Smith North America Packaging and Paper (NAPP). “With this investment, we are decreasing the amount of natural gas consumed at the facility by 20%, substantially reducing CO2 emissions while also enabling faster throughput.”
Reducing natural gas usage at the Columbia box plant will yield an estimated 740-ton decrease in annual CO2 emissions. The new installation includes Baviera Steam Systems’ Condensate Recovery Unit along with Digital Steam Pumps capable of managing the pressure required for corrugating using lightweight and heavyweight papers. Continuous heat transfer control solutions installed with the steam system help to ensure greater consistency, improving control room management and eliminating the need for operator tweaks that can impact long-term performance.
The new technologies also reduce downtime needed to adjust steam pressure when changing paper weights or fluting settings, boosting overall volume capacity at the plant by up to 5%. Faster, simplified changes between board grades with the upgrade will also reduce manufacturing waste.