S.B.R. Solutions Upgrades Steam and Condensate System at PM1 of Cartiere di Guarcino to Enhance Efficiency and Flexibility

S.B.R. Solutions has successfully completed a major technological upgrade of the steam and condensate system in the dryer section of PM1 at Cartiere di Guarcino, aimed at improving operational efficiency, process responsiveness, and energy optimization, particularly for the production of specialty decorative papers.

As energy costs continue to rise across the paper industry, the adoption of advanced plant engineering solutions has become increasingly critical. This project represents a strategic step toward modernizing legacy infrastructure and enhancing production performance.

Project Objectives and Strategic Focus

The upgrade was designed with the following key objectives:

• Simplification of plant architecture

• Improvement in operational efficiency

• Increased responsiveness to production changes

• Enhanced flexibility for a wide range of paper grades

Particular emphasis was placed on optimizing performance for specialty decorative papers, which require high process adaptability and precision control.

Methodological Approach and Initial Challenges

The initiative originated from the need to overcome the limitations of an outdated steam and condensate system that had been in operation for several decades and was no longer aligned with modern production requirements.

S.B.R. Solutions adopted a comprehensive methodology that included:

• Detailed on-site data collection

• Historical data analysis

• Simulation of future operating scenarios

Close collaboration with machine operators played a crucial role in identifying operational bottlenecks and opportunities for improvement. Based on this analysis, clear targets were established:

• Efficient management under variable operating conditions

• High flexibility across production ranges

• Removal of constraints from legacy dryer design

• Maximum responsiveness to process variations

A key challenge was achieving the optimal balance between performance and energy efficiency, often competing priorities in industrial systems.

Engineering Development and Technical Solutions

The design phase was carried out through close cooperation between the mill’s technical team and S.B.R. Solutions, fostering a partnership approach beyond the traditional client-supplier model.

Key engineering principles included:

• Flexible steam distribution across the dryer section

• Optimized condensate line design for reduced energy consumption

• Solutions aimed at maximizing system responsiveness

The project required advanced and non-conventional engineering, including:

• Redesign of the vacuum system and vent lines

• Development of an innovative aerothermal configuration

• Integration between the steam-condensate system and machine ventilation

These solutions collectively contributed to a more efficient and adaptable plant layout.

Implementation and Operational Results

Thanks to high-quality detailed engineering and effective project management coordination, installation was completed smoothly.

The start-up of the upgraded system, carried out in early February 2026, was rapid and trouble-free. From the initial operational phase, the system demonstrated:

• Improved process stability

• Enhanced control capabilities

• Immediate operational benefits

Future Developments

Building on the success of the upgrade, the project has opened the door to further innovation. A new system for fume recirculation is currently under development, aimed at maximizing the recovery of process energy that would otherwise be lost to the atmosphere.

Conclusion

This project highlights S.B.R. Solutions’ capability to deliver advanced, tailor-made engineering solutions that address both operational and energy challenges in the paper industry. The upgrade positions Cartiere di Guarcino to achieve higher efficiency, improved flexibility, and sustainable production growth.