Large Scale Stock Preparation Line For Recycled Fiber Processing

DS Smith and technology provider ANDRITZ have completed the installation and start-up of an advanced stock preparation line and reject treatment system at the Porcari mill. The newly commissioned digital infrastructure handles the technical demands of manufacturing packaging materials from completely recycled fiber for the e-commerce and consumer goods sectors.

Client Operations and Production Objectives
DS Smith operates within the fiber-based packaging sector, supplying the fast-moving consumer goods and e-commerce industries. At its facility in Porcari, Italy, the primary operational objective was to process a wide variety of recovered paper grades into packaging materials using 100 percent recycled fiber. The core technical challenge involved maintaining consistent output quality and process stability despite the inherent physical variability of raw recycled paper materials.

Technical Solution for Recycled Fiber Processing
To address these production requirements, the facility deployed a comprehensive stock preparation line and reject treatment system supplied by ANDRITZ. The central component of this installation is a high-capacity drum pulper, designed to process up to 1,650 tons per day. The system architecture also includes specialized screens and low-consistency cleaners. Furthermore, the reject treatment framework incorporates an industrial shredder and heavy-duty compactors to systematically manage the waste byproducts generated during the initial pulping and coarse screening phases.

Operational Mechanics and Implementation
The equipment was selected specifically for its capacity to execute gentle pulping mechanics while simultaneously extracting coarse contaminants from the incoming recovered paper stream. The integrated screens and low-consistency cleaners are engineered to sustain high stock quality and optimize energy consumption, functioning effectively even when raw material conditions fluctuate. Throughout the deployment phase, ANDRITZ supported the facility integration by providing basic and detailed engineering, installation supervision, system commissioning, and comprehensive operator training to ensure operational readiness.

Measured Impact on Packaging Production
The integration of the stock preparation line stabilized site operations and standardized fiber quality for the Porcari facility. Alessandro Romagnolo, Project Head at DS Smith, indicated that the operational system enables the facility to efficiently process various recovered paper grades and reliably manufacture packaging papers derived entirely from recycled fibers. By automating the extraction of contaminants and streamlining the management of pulping rejects, the installation improves raw material efficiency and maintains continuous production stability for industrial packaging outputs.

Edited by Aishwarya Mambet, Induportals Editor, with AI assistance.

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