Energy transformation as a key to profitability at MM Gernsbach
The European paper industry is facing significant challenges: high and volatile energy prices, continuously evolving regulatory requirements, and the high technical complexity of existing production and energy supply systems. At the same time, a wide range of decarbonization options is available—ranging from efficiency measures and electrification to high-temperature heat pumps, utilization of residual materials, renewable electricity generation, energy storage systems, and power purchase agreements (PPAs). These measures compete for limited investment budgets and must be consistently coordinated while taking regulatory constraints—such as grid tariff structures—into account.
The presentation introduces a proven, model-based approach to transformation planning. At its core is a digital twin that represents production and energy supply systems, including their technical, economic, and regulatory interactions, within a mathematical model. Based on this representation, mathematical optimization explores a high-dimensional solution space comprising a large number of technology and operational combinations and identifies robust, total-cost-optimal transformation pathways. The approach enables adaptive planning and systematic re-optimization in response to changing market and regulatory conditions.
As a case study, the transformation planning for MM Gernsbach GmbH is presented. The model includes, among other elements, cardboard production with the drying section represented down to cylinder level, steam and condensate systems, coating processes and heat recovery, as well as the complete energy supply system and relevant residual material streams. The analyzed solution space comprised, among others, on-site renewables (hydropower, wind, and photovoltaic systems), power purchase agreements (PPAs), battery and high-temperature thermal storage, electric boilers, high-temperature heat pumps, biomass and residual material utilization, as well as operational optimizations such as cascade systems, steam turbine operation, and radiant drying.
The results demonstrate that economic and environmental objectives in the paper industry do not have to be contradictory but can be aligned through a holistic portfolio of measures. The digital twin enables MM Gernsbach to
• holistically assess measures and their interactions under different future scenarios,
• derive resilient strategies for optimizing energy costs and emissions, and
• respond flexibly to market and regulatory changes and make well-founded investment and operational decisions.
The digital twin calculations thus provide a robust and transparent decision-making basis for the further development of strategic investment and operational strategies at the MM Gernsbach site.