IBS strips dry strength additives from European packaging machine to unlock 865000 euros in annual savings

Mechanical precision overtakes chemical dependency in the wet end

The packaging paper sector has spent the better part of the last decade chasing incremental gains, often relying heavily on chemical additives to hit stringent strength targets. However, a recent optimization project in Europe proves that mechanical precision in the forming section can still outmaneuver chemical dependency. IBS Paper Performance Group has successfully eliminated the use of dry strength additives on a European packaging paper machine, unlocking €865,000 in direct annual savings.

Operating at a capacity of 115,000 metric tons per year, the machine in question underwent a targeted technological upgrade in its wire section. The core of the intervention was the installation of the iTABLE maXX system across both layers of the machine. According to IBS iTABLE maXX enables annual savings of 865000 €, this hardware upgrade was paired with a comprehensive audit and subsequent optimization of the vacuum system and forming zone.

Redefining burst strength without additives

The results challenge the conventional wisdom that high burst strength requires heavy chemical support. By refining the mechanical dewatering and sheet formation process, the mill improved sheet formation by up to 12 percent and boosted the formation profile by an impressive 38 percent. Crucially, burst strength—a non-negotiable metric for packaging grades—increased by 10 percent without a single drop of dry strength additive. Additionally, starch concentration in the process was reduced by 2 percent.

In the highly competitive landscape of 2026, where European mills face relentless pressure from fluctuating raw material and energy costs, finding structural cost reductions is paramount. The €865,000 annual saving from this project drops straight to the bottom line, delivering a return on investment in just a few months. This aligns with the broader industry push to reduce variable costs—particularly expensive chemical inputs—while maintaining or improving physical paper properties. Furthermore, reducing chemical usage inherently improves the cleanliness of the mill's water loops, offering a subtle but important operational and environmental benefit.

The value of targeted wet-end audits

IBS Austria GmbH, headquartered in Teufenbach-Katsch, has built a solid reputation for these highly targeted interventions. With over 250 iTABLE installations globally, the company is demonstrating that the wet end still holds untapped potential for massive cost reductions. The success of this specific project underscores the importance of the preliminary audit. By thoroughly analyzing the existing vacuum infrastructure and dewatering curves, IBS engineers were able to tailor the iTABLE maXX installation to the exact hydrodynamic realities of the machine, ensuring that the mechanical forces applied during formation perfectly compensated for the removal of the chemical strength agents.

This project is a textbook example of how mastering wet-end physics can permanently engineer costs out of the papermaking process, proving that the best chemical additive is sometimes no additive at all. If a mid-sized machine can extract nearly a million euros in savings simply by rethinking its forming section, how much capital is currently being wasted on chemical compensation across the global fleet? Follow The Paper for daily news, market signals and key updates from the global paper, corrugated and packaging industry. — Sigue toda la actualidad del sector en www.thepaper.ai