Techno-economic analysis of lignin-containing micro- and nano-fibrillated cellulose for lightweight linerboard packaging

A key challenge for the paper industry in adopting nanocellulose materials is finding the right balance between production costs and the benefits for specific paper grades, given the industry’s variety of products and processes. This study developed the first model to evaluate changes in steam consumption and other process parameters on a paper machine when incorporating lignin-containing micro- and nano-fibrillated cellulose (LMNFC) as a dry-strength additive, as well as its economic effects. Significant operational differences were observed in steam consumption, dissolved solids in the sewer stream, and production rates when implementing LMNFC in different scenarios. Using the assumption that reductions in basis weight frees up enough drying capacity to offset the additional drying requirements of LMNFC, this led to a 15% reduction in manufacturing costs while maintaining paper strength. A capital payback period of five years was estimated for LMNFC production, with a minimum selling price of $243 per ton. It is important to evaluate both process dynamics and dual cost metrics (cost per ton and cost per area), when analyzing the impact of LMNFC on linerboard production. While LMNFC increases the cost per ton, the lower cost per MSF underscores its material efficiency and economic benefits, particularly for lightweight grades.