European Environmental Database for Cartonboard and Carton Production - Pro Carton 2019

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BIOECONOMY
Unit
European Environmental Database for
Cartonboard and Carton Production
Malin Johansson and Michael Sturges
RISE Bioeconomy Report No: Not applicable
Restricted distribution: For use only with the permission of Pro Carton
THIS REPORT IS CONFIDENTIAL and only for use by LCA experts.
Pro Carton
Association of European Cartonboard and Carton Manufacturers
Todistrasse 47
CH 8027 Zurich
Switzerland
www.procarton.com

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Contents
Contents ..................................................................................................... 2
1 Introduction......................................................................................... 3
2 Description of the production process ................................................. 4
2.1 General description of cartonboard and folding cartons .................................. 4
2.2 Types of cartonboard ......................................................................................... 4
2.3 Cartonboard production .....................................................................................5
2.4 Carton production .............................................................................................. 9
3 Description of the Pro Carton environmental database for LCA .......... 11
3.1 Boundaries ........................................................................................................ 12
3.2 Representativeness ........................................................................................... 14
3.3 Data collection .................................................................................................. 15
3.3.1 Questionnaire ............................................................................................ 15
3.3.2 Allocation of inputs and outputs ............................................................... 15
3.3.3 Validation .................................................................................................. 15
3.4 Material input and output ................................................................................ 15
3.4.1 Raw material .............................................................................................. 15
3.4.2 Chemical inputs ......................................................................................... 16
3.4.3 Material outputs ........................................................................................ 16
3.4.4 Wastes/Residues ....................................................................................... 16
3.5 Energy input and output ................................................................................... 16
3.6 Emissions to air ................................................................................................ 17
3.7 Emissions to water ............................................................................................ 18
3.8 Transport .......................................................................................................... 18
4 Data ................................................................................................... 20

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1 Introduction
Pro Carton, the European Association of Cartonboard and Carton Manufacturers is
pleased to present this fifth edition of the European Environmental Database for
cartonboard and carton production. This data is representative of the whole industry
and thereby contributes to the growing body of life cycle data in the paper and board
packaging sector.
The aim of this database is to provide life cycle experts with the best possible
environmental data from the industry in order that their analysis and studies will be as
up-to-date and accurate as possible.
Technical experts in cartonboard and carton manufacturing processes have worked
together with LCI experts to provide a database which is based on both technological
knowledge of cartonboard and carton production and LCI study requirements.
This database contains information on the inputs and outputs of the total European
cartonboard and carton industry to the environment, measuring a range of emissions
and reporting weighted averages. The database should not be regarded as a benchmark
for the industry, or as a tool for comparisons between different parts of the industry. If
specific information on a particular cartonboard grade is required, then this should be
requested directly from the manufacturers.
Pro Carton is grateful to its member companies for their willing co-operation in its
compilation. It is anticipated that further updates will be issued on a regular basis.
This report has been prepared by RISE (Research Institutes of Sweden) on behalf of Pro
Carton and the report and data has been subjected to external peer review by ifeu –
Institute for Energy and Environmental Research Heidelberg GmbH, Germany.
For further information, please contact:
Tony Hitchin
General Manager
Pro Carton
hitchin@procarton.com
August 2019

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2 Description of the production
process
2.1 General description of cartonboard and
folding cartons
Folding cartons are small to medium sized “cardboard boxes” made from cartonboard.
They are used to package a wide range of products from foodstuffs – such as cereals,
frozen and chilled food, confectionery, bakery goods, tea, coffee and other dry foods – to
pharmaceuticals, medical and healthcare products, perfumes, cosmetics, toiletries,
photographic products, clothing, cigarettes, toys, games, household and electrical,
engineering, gardening and DIY (do-it-yourself) products.
There are many different types of cartonboard manufactured, all of which can be made
in a variety of different weights (grammages) and thicknesses. The type of cartonboard
and the fibre composition depends on the intended use and the specific requirements.
Usually paperboard is made up of several plies to make the best possible use of the
different types of raw materials and optimise the product performance.
Cartonboard is made from cellulose containing fibres that are produced either from wood
or from recovered paper and board. A combination of the two can be used and there are
various types of fibre that produce different characteristics. For example, shorter fibres
generally give a better bulk and longer fibres give a greater stiffness and so types of fibre
are mixed to produce the desired characteristics.
The fibres can also be treated with various chemicals to improve a variety of properties
such as moisture and grease barriers. Additionally, they can be coated with a range of
barriers to produce cartonboard that can be used in ovens and microwaves and other
specialist packaging. They can also have metal effects added to them to enhance the
appearance of the finished product.
2.2 Types of cartonboard
Solid Bleached Board SBB, (also known as SBS / GZ)
This grade is typically made from pure bleached chemical pulp with two or three layers
of coating on the top surface and one or more layers on the reverse. There are also
uncoated grades. Typical markets include cosmetics, pharmaceuticals, graphics, tobacco
and luxury packaging.
Solid Unbleached Board SUB (also known as SUB / SUS)
This grade is typically made from pure unbleached chemical pulp with two or three layers
of coating on the top surface. In some cases, a white reverse surface is applied. It is
primarily used as beverage carriers for bottles and cans, as it is very strong and can be
made resistant to water. It is used where strength of packaging is important. SUB may

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also be used in the production of liquid beverage cartons and liquid food cartons, but this
application is excluded from the scope of the data collected in this report.
Folding Boxboard FBB (also known as GC /UC)
This grade is typically made of mechanical pulp sandwiched between two layers of
chemical pulp with up to three layers of coating on the top or printing surface and one
layer of coating on the reverse. Typical uses include pharmaceuticals, confectionery,
frozen and chilled foods.
White Lined Chipboard WLC (also known as GT /GD /UD)
This grade is typically made using predominantly recovered paper or recovered fibres. It
is manufactured in a number of layers, each of which use selected grades of raw
materials. It typically has up to three layers of coating on the top or printing surface and
one layer on the reverse. It is used in a range of applications such as frozen and chilled
foods, cereals, shoes, tissues and toys.
The make-up of the total production in Europe is currently as follows SBB/SBS 9.3%;
FBB 39.3%; WLC 51.4% (excluding production of board for liquid beverage
cartons/liquid food cartons).
The average consumption of cartonboard in Europe is approximately 10 kgs per person
per year.
More information and statistics can be found at the Pro Carton website
www.procarton.com.
2.3 Cartonboard production
In Europe, responsible sourcing of raw material for cartonboard which is used for the
production of folding cartons, is from both wood and recovered paper.
The wood raw material comes from sustainably managed forests. Not only are they a
renewable resource, but in Europe forest growth exceeds wood harvested. European
forests are grown and harvested in a carefully controlled and sustainable way – so
successfully that European forests, where most of the raw material comes from, have
grown by an area the size of Switzerland in just 10 years 1 .
To achieve this, European forests owners and operators follow a combination of national,
European and international forest laws and regulations. They can prove forests are
managed through Forest Certification Schemes such as FSC ® and PEFC. A “chain of
custody” certificate demonstrates that the wood used to make cartonboard in Europe
originates from legal and traceable sources.
1
https://www.twosides.info/european-forests/

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Trees also remove and store carbon from the atmosphere. According to the European
GHG inventory, forests of the EU-28 are a net carbon sink, with net CO2 removals by
forests having increased by over 19% between 1990 and 2014. 2
Wood is processed with chemical or mechanical pulping processes to make the wood
fibres suitable for the paperboard making.
Wood contains about 50% water. The dry biomass comprises cellulose, hemicelluloses
and lignin, a hard, brittle material that binds fibres together and small amounts of wood
resins.
In mechanical pulping, the fibres are separated by applying mechanical force to either
debarked logs (roundwood) or smaller chips (refiner mechanical). The heat generated
softens the lignin and results in fibre separation. The pulp is then screened and cleaned
and any remaining fibre clumps are reprocessed.
In chemical pulping, debarked logs are chipped and treated with chemicals under heat
and pressure. This dissolves the lignin and hemicelluloses of the wood and cellulose
fibres can be separated from the cooking liquor. There is a choice of chemicals for
processing. The kraft or sulphate process is by far the more widely used because of its
ability to process all commonly used types of wood and its high rate of chemical recovery.
An alternative raw material source is recovered paper and board. Fibre separation is
achieved by mechanical agitation in water.
Recovered paper and cartonboard has been printed, sometimes varnished and for
packaging applications, often has been glued. In products where high purity and
whiteness is important, it is necessary to remove the printing inks, glues and other
impurities.
After the recovered paper and board has been immersed in water, disintegrated and the
fibres dispersed, heat and/or dispersion agents are used to remove the often sticky
impurities from the fibre surfaces. Then flotation techniques, screening and washing,
sometimes additional bleaching is used to remove any impurities.
Energy sources depend on the way pulp is made and the location of the mill. Chemical
pulping results in a by-product which can be used as an energy source itself for pulping
and where, appropriate, bleaching. In integrated mills the wood by-products also provide
energy, electricity and steam for the manufacturing process. These energy sources are
therefore naturally renewable.
Mechanical pulping and fibre recycling uses energy to separate the fibres. This energy
may be made on-site or supplied from external sources. For on-site generation, several
mills have installed combined heat power (CHP) plants which are very efficient
compared to power stations supplying a national grid.
Water is an essential element for paper and board production. Water acts as a bond
between the fibres and in the production process, is needed for transporting, cleaning,
as a solvent, carrying energy in the form of steam and is used in cooling process units.
Water is usually taken from a nearby surface source such as a lake or river. 95% of the
water used in the industry is cleaned and reused on site. All wastewater is purified at the
2
From Guidelines for calculating carbon footprints for paper-based packaging, CITPA, March 2017

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mill in accordance with European regulations and standards, before being returned to
the environment.
The cartonboard types included in the study are:
Solid Bleached Board, SBB, made from wood, 100% bleached chemical pulps.
Solid Unbleached Board, SBB, made from wood, 100% unbleached chemical pulps.
Folding Box Board, FBB, made from wood, mainly mechanical pulp and some
chemical pulp
White Lined Chipboard, WLC, made from mainly recovered paper and board and
some chemical pulp
The manufacturing process itself for all types of cartonboard is fairly similar. This
diagram shows an overview of how cartonboard is manufactured.
Figure 1
Understanding the manufacturing process
Pulp and recovered fibre is mixed with water. It is then cleaned and refined and pumped to
the cartonboard machine.
A very dilute mixture of fibre and water is put onto the machine. As the water drains, a sheet
is formed. This is then pressed to extract water and passed over steam heated cylinders to
evaporate water. Finally, the board is coated with up to 4 layers of coating and wound into
large reels.
The large reels for the cartonboard machine are sent to the finishing department where they
are cut either into smaller reels or into sheets and packed onto pallets for sale and distribution.
The fibre, either in the form of pulp made from forest thinnings and sawmill residues or
recovered paper, is mixed with water in large hydropulpers until a very fine suspension
is achieved. This is then cleaned to remove any contraries, refined to enhance strength
and then pumped to the cartonboard machine where the cartonboard is manufactured.
In the fibre preparation before the board making functional additives are used. The
additives provide some degree of water resistance (hydrophobicity) and add internal and
surface strength to the product.

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The dispersed fibres with the functional additives and water mixture from the
preparation plant, is pumped to the cartonboard machine and this very thin mixture,

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The manufacture of Folding Box Board, FBB, is also to a large degree integrated but
usually the required chemical pulp is purchased. The mechanical processing of wood
requires electricity. Bark, wood residues and heat recovery from the pulping process are
used for process steam and heat.
Due to the high degree of integration these types of mills can utilise wood residues as a
biofuel covering a significant part of the energy consumption. The fact that these mills
have their own pulping processes means that energy and water are consumed in addition
to the needs from the cartonboard making process.
White Lined Chipboard, WLC, is typically made in non-integrated processes
meaning that all the main raw materials (i.e. recovered paper, chemical pulps etc.) are
purchased and then prepared before the board making process. In comparison to
integrated manufacture this requires less energy and water (no pulping processes).
Usually there are no options for biofuels, which means that natural gas and electricity
are the main energy source.
2.4 Carton production
Folding cartons are very versatile and can be designed in a wide variety of ways. For a
variety of examples, please visit www.procarton.com
Carton production starts with the cartonboard delivered from the mills.
Below is a diagram showing a typical layout of a carton production plant.
Figure 2
Typical layout of a carton production plant

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The design for a carton is either sent to the carton producer or developed by them. The
graphics are prepared on a computer and colour separation is carried out. From this a
printing plate for each colour is prepared. At the same time a “lay out” is designed.
The cartonboard in either sheets or reels, is loaded into the printing machine and printed
in one pass with each colour being added in turn. A variety of printing processes may be
used, including for example lithographic, flexographic and gravure processes. In some
cases, digital printing may also be used. This is an emerging technology that is expected
to become more important for carton production in the future.
Many cartons can be printed on each sheet of cartonboard and so a layout is worked out
to ensure that as little cartonboard as possible is left unused. This layout is also used to
prepare the cutting and creasing forms that are used later in the production process.
Most cartons are printed using six colours at a time but less or more can also be used. As
well as the colours, a varnish to improve gloss, or to add a highlight, is also usually
printed after the colours.
At the end of the print machine, the sheets are stacked up and moved to the next stage of
production – cutting and creasing. The printed sheets of cartons are taken to a machine
that cuts the cartons and also puts in the creases that enable it to be folded in a later
operation. This is done using a form into which are set knives and creasing rules to
achieve the desired result. It is also possible to add embossing during this operation.
Here again, accuracy is critical to ensure the cuts and creases are in exactly the right
position.
The individual cartons are then stacked up and passed through to the next stage of
production, folding and gluing.
When the cartons have been cut and creased, they are moved through to the gluing line
where the cartons are folded and glued. This is done on high speed machines that, in one
operation, fold the creases and glue the seams where necessary.
The cartons are then packed for shipment to the carton user who puts them onto their
packing line for filling.

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3 Description of the Pro Carton
environmental database for LCA
Life Cycle Assessment (LCA) is a tool for the systematic evaluation of the environmental
aspects of a product or service system through all stages of its life cycle. LCA provides an
adequate instrument for environmental decision support. Reliable LCA performance is
crucial to achieve a life-cycle economy. The International Organisation for
Standardisation (ISO), a world-wide federation of national standards bodies, has
standardised this framework within the series ISO 14040 on LCA.
Figure 3
LCA methodology
Goal and
scope
definition
Inventory
analysis
Interpretation
Impact
assessment
Source: ISO 14040 3 /ISO14044 4
1. Goal and Scope Definition, the product(s) or service(s) to be assessed are defined, a
functional basis for comparison is chosen and the required level of detail is defined;
2. Inventory Analysis of extractions and emissions, the energy and raw materials used,
and emissions to the atmosphere, water and land, are quantified for each process, then
combined in the process flow chart and related to the functional basis;
3. Impact Assessment, the effects of the resource use and emissions generated are
grouped and quantified into a limited number of impact categories which may then be
weighted for importance;
3
ISO 14040:2006 Environmental management -- Life cycle assessment -- Principles and framework
4
ISO 14040:2006 Environmental management -- Life cycle assessment -- Requirements and standard

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4. Interpretation, the results are reported in the most informative way possible and the
need and opportunities to reduce the impact of the product(s) or service(s) on the
environment are systematically evaluated.
Pro Carton collected the following inputs and outputs from the production processes:
Material inputs and outputs
Energy inputs and outputs
Emissions to air, water and soil
Transport of raw materials
This report gives average inventory data of the partial life cycle. The data provide a basis
to assess the potential environmental impacts of the use of paperboard in the life cycle -
production phase, distribution, use and final disposal - of products. Data from upstream
and downstream operations as well as entire impact assessment would be needed before
environmental impacts could be assessed for the full life cycle.
3.1 Boundaries
This report includes detail on binders, functional additives, production of purchased heat
and cartonboard waste from the converting process. The overall cut-off criterion for total
material inputs is 0.05% of the sold product (in total < 0.5 kg per tonne sold product).
The data in chapter 4 are gate-to-gate data, as shown in the diagram below: inputs and
outputs from the production sites (i.e. cartonboard production and carton converting
processes). These data provide the basic information needed to compile cradle-to-gate
and/or cradle-to-grave Life Cycle Inventories (LCI) 5 . Impacts associated with upstream
and downstream processes are not included in the inventory data.
Figure 4
Understanding different system boundaries
The diagram below provides a detailed overview of the unit processes considered within
the datasets. Data is not provided broken down according to the individual unit
processes. Rather, the information is presented as a single black box covering both
production of the cartonboard and carton converting processes.
5
Cradle-to-gate LCIs include inputs and outputs from upstream processes and gate-to-gate processes,
cradle-to-grave LCIs include also the inputs and outputs from downstream processes

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Figure 5
Unit processes included in the analysis

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Subsequently, the dataset represents the European averages for the board production,
including typical data for the converting and printing of the paperboard. Data for carton
converting processes was provided by the members of ECMA (European Carton Makers
Association). 6
Information about transport can be found in chapter 3.8. The emissions from transport
are not included in the data in chapter 4, but can be calculated by the user based on the
distances reported and the application of standard carbon factors for the various modes
of transport detailed.
3.2 Representativeness
The data collected for the paperboard production represent 69% (> 5,000,000 tonnes)
of the European production capacity of paperboard. Participating mills are located in
Austria, Germany, Finland, Italy, Netherlands, Slovenia, Sweden and the UK. The annual
production of the production sites varies from 60,000 – 520,000 tonnes net saleable
product.
The data thus represent the average European technology for 2017.
The data collected for each grade cover:
99% of the production for SBB/SUB
71% of the production for FBB
52% of the production for WLC.
Pro Carton’s aim was to develop one dataset for paperboard. Participating mills agreed
to the following procedure for calculating such a dataset:
From the response through the questionnaires the consultant calculated separate
datasets representing the weighted averages for SBB (solid bleached board), SUB
(solid unbleached board), FBB (folding box board) and WLC (white lined
chipboard).
Of the total European paperboard production for these grades, 9.3% is SBB/SUB,
39.3% is FBB and 51.4% is WLC. These percentages have been used to calculate the
averages reported in chapter 4.
The data in chapter 4 represent the sum of
o 9.3% of the inputs and outputs of SBB/SUB,
o 39.3% of those of FBB and
o 51.4% of those of WLC.
6
More information about ECMA can be found at www.ecma.org

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3.3 Data collection
3.3.1 Questionnaire
The questionnaire was developed from the Pro Carton questionnaire that was used in for
data collection in 2015.
The questionnaire looks at the production sites as a black box, requesting information
about annual inputs and outputs. Internal data on energy production and consumption
were asked, but only used for checking the consistency of the submitted energy
information. These internal flows are not reported in chapter 4.
3.3.2 Allocation of inputs and outputs
Most of the mills produce only one grade of product: SBB, SUB, FBB or WLC. Therefore,
allocation of inputs and outputs to different products was needed only in exceptional
cases where a mill produces more than one grade of paper.
Mills provided information on the allocation of inputs of raw materials to coproducts
based on consumption in the different production processes.
Causality is difficult for other inputs and outputs. Therefore, these were allocated
to the co-products based on mass of production.
In case the mill produces other products (e.g. market pulp, sold energy), the mills
reported only the inputs and outputs that were allocated to the cartonboard
production.
The allocation that was applied reflects the underlying physical relationships
between the processes. For this purpose a spreadsheet was developed to help
calculate the data that were then introduced in the questionnaire for the cartonboard
production.
No allocation was made to by-products, so the reported inputs and outputs include the
production of these by-products.
3.3.3 Validation
A rough check for C-balance, energy, water and mass balances was included in the
questionnaire.
3.4 Material input and output
3.4.1 Raw material
Both primary fibres and recycled fibres are used for the production of paperboard.
The wood input is reported as dry weight. It originates from final fellings, thinnings and
sawmill residues. Almost 70% of the roundwood consumed for the cartonboard produced
by the participating mills is Chain of Custody certified under a forest management
system, FSC ® and/or PEFC .

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Non-integrated mills buy mechanical, chemical and de-inked pulp and recovered paper.
The pulp data are reported in bone dry 7 weight, which is normally 90% of the wet (air
dry) weight.
WLC is produced mainly from recovered fibres. The recovered paper is reported as total
bone dry weight including other materials (sand, metal, plastics, wood). In European
countries the water content of recovered paper is generally assumed to be about 10%.
The content of other materials in the recovered paper varies between 2%-5%, on average
it is 3%. It is estimated that about a third is due to rejected materials that were associated
with the previous use of the recovered paper (for example, staples, paper clips, tags,
adhesive labels, unrecovered fibres etc). The remaining two thirds is material that is not
in any way associated with the previous use of the paper (for example, foreign items such
as textiles, plastic packaging, glass, sand, grit etc).
Coating pigments (Calcium carbonate and clay) and binders make up for about 12% of
the sold paperboard.
3.4.2 Chemical inputs
The mills were asked to report the main additives. These were listed in the questionnaire.
The amounts are reported in bone dry weight.
3.4.3 Material outputs
The main output is paperboard. The average dry content is 92.3% (with a range of 92%-
94%). The main sold by products from the production of paperboard are pine oil and
bark.
3.4.4 Wastes/Residues
The waste/residues are reported as dry weight. The EWC (European Waste Catalogue)
numbers have been used as far as possible to identify the different solid wastes/residues.
3.5 Energy input and output
Fuel inputs to the sites have been reported in GJ. The lower calorific values have been
used to calculate GJ from m3 or tonnes of fuel. Fossil fuel and biomass fuel have been
reported separately.
Input of electricity and steam to the sites is also reported. The electricity and steam that
is produced at the site itself is not reported. Some mills are selling energy externally in
the form of electricity, steam or heat. In the inventory these are not reported as sold
products and their input and output data is not included in the inventory results.
The reported voltage of the purchased electricity is medium (1-24Kv) or high (>24kV)
voltage. The electricity is not always purchased from the grid: it is partly purchased from
external energy services with e.g. natural gas as fuel.
7
Bone dry weight: weight without any water

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The production sites are treated as a black box, giving data on inputs and outputs only.
For fully integrated mills with chemical pulping, energy is recovered in this box through
burning of black liquor, wood residues and bark from wood coming in at production sites.
Additional use of fossil fuels is avoided by using these mill-born biofuels.
3.6 Emissions to air
Emissions from external fuel combustion (e.g. transport, electricity generation for the
public grid) are not included in the data.
The emissions of particles, NOx, SOx and CO arising at the mill are based on
measurements. Particle size was not specified.
The CO2 figures are calculated for fossil fuel origin, using the IPCC 2006 8 . Methane and
nitrous oxide hardly contribute (less than 0.5 %) to the CO2-equivalents for these fuels.
kg CO2/GJ
Natural gas 56
Heavy fuel oil 77
Light fuel oil 74
Diesel oil 74
Hard coal 95
Peat 106
The calculation of CO2 from wood-based fuels is more problematic.
The moisture content may vary from 20% (black liquor) to 70% (sludges) and it affects
the net heat value. The corresponding CO2-factor for fuels expressed as their net heat
value varies between 106 and 150 kg CO2/GJ.
The factor 126 kg CO2/GJ of wood-based fuel has been used to calculate the biomassbased
CO2 emissions in case the real emissions were unknown.
Normally in LCA, the CO2 originating from biomass are not considered to contribute to
GWP (global warming potential). This is due to the fact that the releases of CO2 are
compensated for by the CO2 that has been taken up out of the atmosphere during the
growth of the biomass.
In principle, peat is a bioenergy, but for LCA purposes it is regarded as a fossil fuel.
Therefore, the CO2 emissions from peat are reported as CO2 from fossil fuel.
8
2006 IPCC Guidelines for National Greenhouse Gas Inventories, http://www.ipccnggip.iges.or.jp/public/2006gl/index.html.

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3.7 Emissions to water
When paperboard mills use surface water, they do not consume this water during the
production process. After (re)use it is returned to the rivers or seas as cooling water and
purified effluent water. A limited amount of water is evaporated in the drying section of
the paperboard production.
All mills have some sort of effluent water treatment: mechanical, chemical and biological
aerobic treatment and in some cases also anaerobic treatment of the effluent.
A few mills send their effluent to external wastewater treatment plants. The emissions
from the mills with partly external wastewater treatment are not included in the averages
that are reported.
Most of the mills with their own wastewater treatment measure all of the parameters for
substances in process water included in the inventory. For mills where data points were
not available for certain parameters, their production was excluded from the calculation
of the weighted average emissions of this parameter.
3.8 Transport
The transport distances of wood raw materials from the harvesting sites in the forests to
the mills have been reported separately for trucks, rail and ships. The trucks and rail
wagons are normally loaded to full capacity but go back empty. The trucks carry 40-44
tonnes of wood. This information has been collected on a species-species basis for each
mill, considering the wet weight of the wood. Distances and tonnages of wood delivered
have then been used to calculate the total t.km for delivery of wood by each mode of
transport (truck, rail and boat). This is then used to calculate the t.km/t of production
for each grade (WLC, FBB, and SBB/SUB) at each mill. This is calculated on a mill-bymill,
input-by-input basis. A weighted average t.km is then calculated based on the
relative production share of each mill.
A similar approach is applied for calculating the transport requirements for recovered
paper. Transport distances from point of origin of the recovered paper bales to the mills
have been reported on a recovered paper grade-by-grade basis for each mill. Distances
and tonnages of recovered paper delivered have then been used to calculate the total t.km
for delivery of recovered paper by each mode of transport (truck, rail and boat). This is
then used to calculate the t.km/t of production for each grade (WLC, FBB, and SBB/SUB)
at each mill. This is calculated on a mill-by-mill, input-by-input basis. A weighted
average t.km is then calculated based on the relative production share of each mill.
Generally, the lorries are loaded to full capacity. On the return trip it is estimated that
40% of the trucks return empty.
Assuming this is transported by a truck with a loading capacity of 40 tonnes this means
that this figure has to be used in combination with data on inputs and outputs for
transport by a 40t truck.

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Transport of the residues was not included in the questionnaire as this was seen to be
part of the residue treatment. During the discussions with the technical experts it became
clear that the transport of rejects is mainly to nearby landfill or other treatment process,
3-30 km.
Data was also collected from the paper mills on average delivery distances and modes of
transports to their customers. This data was provided on a product-by-product basis and
was used to calculate a weighted average t.km for delivery of paper to the converting
plants.
However, any one carton converting plant will, of course, source the substrates they use
from many different suppliers. Therefore, the values presented in the inventory are only
indicative and in practice users of the data may wish to consider delivery of materials on
a case-by-case.

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4 Data
The data in the table represent inputs and outputs per tonne net sold cartons, including
cartonboard production and carton manufacturing and printing:
SOLD by-products
Pine oil kg/t 3.68
Bark kg/t 5.10
Raw materials
Softwood
Pine t dry/t 0.04
Spruce t dry/t 0.19
Poplar t dry/t 0.03
Saw Mill Residues t dry/t 0.07
Hardwood
Birch t dry/t 0.06
Other t dry/t 0.03
Saw Mill Residues t dry/t 0.00
Bought Pulp
Mechanical t dry/t 0.017
Sulphate unbleached t dry/t 0.00016
Sulphate ECF t dry/t 0.10

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Sulphite pulp t dry/t 0.017
CTMP t dry/t 0.098
Recovered paper
total t dry/t 0.54
-
Coating pigments and binders
CaCo3 kg dry/t 98.9
Clay kg dry/t 18.22
Potato starch kg dry/t 2.85
Wheat starch kg dry/t 2.71
Corn starch kg dry/t 5.91
Latex kg dry/t 14.8
Polyacrylates kg dry/t 0.85
Polyvinyl acetate kg dry/t 0.48
Functional additives
Aluminium Printing plates kg dry/t 1.46
Al₂(SO₄)₃, Alum kg dry/t 4.02
CaO kg dry/t 0.43
Clay (filler) kg dry/t 0.66

22
Cold glue for boxmaking kg/t 0.67
H₂O₂, peroxide kg dry/t 2.16
H₂SO₄ kg dry/t 2.55
Hot-melts for boxmaking kg/t 0.076
Flexo ink for printing kg/t 0.80
Off set ink for printing kg/t 3.45
Na₂SO₄ kg dry/t 0.21
NaClO₃ kg dry/t 0.81
NaOH kg dry/t 3.10
O₂ kg dry/t 0.58
S kg dry/t 0.049
Modified starch (sizing agents) kg dry/t 5.06
Rosin size (sizing agents) kg dry/t 0.56
Varnish kg/t 11.96
Packaging
plastic stretch/shrink film kg/t 1.17
ENERGY

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BOUGHT FUELS AND ENERGY
Natural gas GJ/t 3.84
Heavy fuel oil GJ/t 0.044
Light fuel oil GJ/t 0.039
Diesel oil GJ/t 0.0046
Hard coal GJ/t 0.67
Peat GJ/t 0.25
RFD Fossil origin GJ/t 0.11
Bark, wood GJ/t 1.24
Bought electricity GJ/t 2.38
EMISSIONS TO AIR
Dust (unspecified) kg/t 0.023
Dust (particle < 2,5 um) kg/t 0.000079
Dust (particle > 10 um) kg/t no data
CO₂ (fossil) kg/t 298
CO₂ (biomass) kg/t 558
CO₂ used in process kg/t 17
SOx (as SO₂) kg/t 0.13

24
NOx kg/t 0.40
WATER
Water input total m3/t 31.14
Ground water fossil/non-renewable m3/t 0.43
Ground water non fossil m3/t 6.09
Surface water m3/t 24.54
Municipal water supply m3/t 0.056
Water outputs total m3/t 29.95
Thermally polluted (only) water m3/t 13.28
Process Water m3/t 16.67
Substances in process water
Chemical Oxygen Demand (CODCr) kg/t 4.62
Biological Oxygen Demand (BOD 5) kg/t 1.34
Total suspended solids kg/t 0.66
Total Organic Carbon (TOC) kg/t 1.89
Total Nitrogen kg/t 0.058
Total Phosphorus kg/t 0.0052

25
AOX as Cl- kg/t 0.0057
RESIDUES/WASTE
ashes kg dry/t 9.60
lubricant residues kg dry/t 0.079
green liquor sludge kg dry/t 0.44
lime mud kg dry/t 3.83
other hazardous waste kg dry/t 0.15
fibre (primary sludge) kg dry/t 13.51
biological treatment sludge kg dry/t 8.32
bark and wood kg dry/t 5.29
rejects from recovered paper
processing kg dry/t 21.83
TRANSPORT
Wood
truck tonkm/t 186
train tonkm/t 72
ship tonkm/t 40
Recovered paper
truck tonkm/t 43
train tonkm/t 6

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ship
tonkm/t 0
Sheets to converter
truck tonkm/t 541
train tonkm/t 703
ship tonkm/t 2099 9
9
Includes all distribution, including deliveries to non-European customers.

27
Through our international collaboration programmes with academia, industry, and the public
sector, we ensure the competitiveness of the Swedish business community on an international
level and contribute to a sustainable society. Our 2,200 employees support and promote all
manner of innovative processes, and our roughly 100 test beds and demonstration facilities are
instrumental in developing the future-proofing of products, technologies, and services. RISE
Research Institutes of Sweden is fully owned by the Swedish state.
I internationell samverkan med akademi, näringsliv och offentlig sektor bidrar vi till ett
konkurrenskraftigt näringsliv och ett hållbart samhälle. RISE 2 200 medarbetare driver och stöder
alla typer av innovationsprocesser. Vi erbjuder ett 100-tal test- och demonstrationsmiljöer för
framtidssäkra produkter, tekniker och tjänster. RISE Research Institutes of Sweden ägs av
svenska staten.
RISE Research Institutes of Sweden / RISE Innventia AB
Box 5604, 114 86 STOCKHOLM, Sweden
Telephone: + 46-8-676 70 00
E-mail: info.innventia@ri.se, Internet: www.ri.se