BillerudKorsnas Gruvon Production Facility Expansion, Gruvon, Varmland County, Sweden


BillerudKorsnas-Gruvon facility

Sweden-based renewable packaging material manufacturer BillerudKorsnäs has announced its plans to expand its manufacturing facility in Gruvön, Värmland County, Sweden, in December 2016. The expansion is scheduled for completion in the first quarter of 2019.

The Skr5.7bn ($621m) project will add a new board machine with an annual capacity of 550,000t at the site. It is the single biggest investment made by BillerudKorsnäs in its history, and one of the largest ever in Sweden.

The project will help BillerudKorsnäs to meet the growing global demand for sustainable packaging solutions in the food and beverages industry.

Purpose of Gruvön production facility expansion

BillerudKorsnäs specialises in the production of renewable, fibre-based packaging products and solutions. The company also specialises in liquid packaging board and other cartonboard.

BillerudKorsnäs manufactures a range of products at the facility, including kraft paper, sack paper, liquid board, cup stock, market pulp and other corrugated products. The facility is equipped with three pulp lines, six paper machines, a coating machine and two flash driers.

The global demand for liquid packaging board and other cartonboards has been steadily increasing as brand owners and consumers are making more environment-friendly choices; BillerudKorsnäs' existing capacity is not sufficient to meet the growing demand.

Details of Gruvön facility expansion

BillerudKorsnäs has been investigating the feasibility of adding a new board machine at the site since 2015 in order to meet the growing demand for its products. Availability of renewable raw material from sustainably managed forests in the Nordic region was a major factor is assessing the feasibility of the alternatives.

The expansion project includes the addition of a new Voith XcelLine board machine at the Gruvön plant along with rebuilding of the existing pulp mill. The project will streamline BillerudKorsnäs' production structure by transferring existing paper production at the Gruvön site to other sites. Production of high-quality fluting at the site, however, will not be affected.

The project will provide BillerudKorsnäs with a solid foundation for addressing the need for sustainable packaging. Production at the facility is expected to be fully operational by 2023.

Details of the new XcelLine board machine

Voith is supplying its XcelLine board machine to be installed at the facility, which offers fast and easy start-up. Voith will also supply a Duo DII hybrid former, a Tandem NipcoFlex shoe press and a VariFlex L winding unit.

A drying section featuring EvoDry steel cylinders and a number of coating and calendaring stations will also be supplied by Voith. The supply package also includes Voith Papermaking 4.0 to enable digital control of paper production.

Products manufactured at the Gruvön facility

The new board machine will enable the Gruvön facility to manufacture sustainable packaging products for the food and beverages industry. Smart packaging solutions based on renewable materials are being preferred as they can limit the use of fossil fuels and reduce climate impact; they also reduce littering and increase food safety.

Approximately 50% of the plant's production will be dedicated towards liquid packaging board, while the remaining 50% will include folding boxboard, food service board and kraftliner.

Contractors involved

NCC has been contracted to perform earth, foundation and concreting works under a Skr950m ($101.6m) contract.

Sweco is responsible for construction management of the new board machine, as well as for structural design of the rebuild of the existing pulp mill.

Pöyry has been contracted to provide detailed engineering services for the new board machine. The company has been involved in the project since 2014, providing pre-project engineering services to convert the investment plan into a feasible technical concept.