AB „KLAIPEDOS KARTONAS“
ENVIRONMENTAL REPORT
2010
AB “KLAIPEDOS KARTONAS”
The
company
“Klaipedos
kartonas”,
functioning for more than a hundred years, is
currently the largest cardboard producer and
waste paper processor, as well as the only
producer of raw goffered cardboard in the Baltic
states.
The Company expands its activities every
year and occupies leading positions in the Baltic
Region. In the year 2010 the turnover of Public
Limited
“Klaipėdos
kartonas”
reached
114,7 million litas.
The sales outside Lithuania account for
more than 60 % of the whole turnover.
Manufactured products are exported to many
countries – Ukraine, Russia, Poland, Latvia,
Estonia and other.
Structure of sales 2010
Estonia Latvia Other
8%
1%
Czech 3%
2%
Lithuania
35%
Poland
17%
Belarus
4%
Ukraine
24%
Russia
6%
The company is situated in the Klaipeda
port. Profile of the company is closely linked to
environmental protection. All production of the
company is produced from secondary material –
waste paper. Every ton of waste paper saves 15
trees, 30 m3 of water, and 500 kg of oil.
Nemuno g.2, LT-5800 Klaipėda
Tel. (8-46) 39 56 01, faks. (8-46) 39 56 00
El.paštas: info@kartonas.lt
http: www.kartonas.lt
AB „Klaipedos kartonas“
Evironmental report 2010
-2-
PRODUCTION
The main product of "Klaipedos kartonas''
is testliner and fluting - a raw material for
production of corrugated cardboard.
JSC “Klaipedos kartonas” also has energy,
mechanic, automatics and wastewater treatment,
logistics departments, laboratory.
Sins July of 2007, a new honeycomb line is
operating succesfully and producing honeycomb
filling. Cardboard honeycomb filling is widely used:
 In the furniture industry;
 In the construction industry (for inside
doors, plasterboard constructions, wall
panels, exhibition stands);
 For packaging;
 In production of pallets
The main part of our production is
manufactured by the "Inverform" type machine of
the English company "Beloit Walmsley". This
allows 100 000 thousand tones of testliner and
fluting to be produced in the company in one
year.
Production (honeycom b), t.m 2
9194
10000
9000
8000
7000
6473
6592
2008
2009
6000
Production (testliner and fluting), t
120000
100000
80000
5000
4000
3000
98885
93541
95390
88608
87133
78685
69801
70181
57524
2000
1042
1000
0
2007
2010
60000 46472
40000
20000
0
2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
The company consists of the following
main production units:
 Waste paper processing workshop
 Cardboard workshop
 Cardboard production
workshop
AB „Klaipedos kartonas“
Evironmental report 2010
-3-
MANAGEMENT SYSTEMS,
CERTIFICATES
In 2001, the company implemented
quality management system in accordance to the
standard ISO 9001.
The company has implemented and
certified the environment protection management
system in accordance to the standard ISO 9001in
September 2004. The certification was carried out
by audit company KEMA from the Netherlands.
Since 2003 the independent international
laboratory Isega awarded the company with the
certificate, which ensures and certifies safe and
nonhazardous use of the products for packaging
of foodstuffs.
In 2010 of October integrated (quality
and environmental) manegement system was
succsesfully recertified by the JSC Det Norske
Veritas. Certificate is valid until 31 October 2013.
In May of 2009 honeycomb production is
certified for FSC® (Forest Stewardship Council®)
Chain-of-Custody. Certificate based on FSC-STD40-004 and FSC-STD-40-007.
Sertificate Registration Code – SW-COC004078, license code – FSC-C007955.
ENVIRONMENTAL POLICY
AB “Klaipedos kartonas” produces row
material for corrugated cardboard, cardboard
products and provides the supply services is
situated on the shore of Curonian lagoon close to
the city centre. Therefore, company is determined
to operate in a environmentally friendly way.
Top management of the company commits to
comply with environmental legal and other
requirements and:
 Aims for continuous improvement of
environmental performance by reducing any
negative impact to the environment from the
company’s activities by application of integrated
quality
and
environmental
management
procedures.
 Commits rationally use water and energy
resources by application of modern production
technologies and ensuring high quality of
production.
AB „Klaipedos kartonas“
 Commits to apply pollution prevention
principles in all activities.
 Commits to monitor environmental impact
and to set objectives for continuous reduction of
this impact.
 Commits to involve every employee and
those working on behalf of the company in the
environmental management activities; to inform
about such activities all interested parties; to
integrate environmental protection issues in
training programmes for employees.
TOP MANAGEMENT OF THE COMPANY TAKES RESPONSIBILITY
FOR IMPLEMEMTATION OF THIS POLICY
ENVIRONMENTAL IMPACT,
ENVIRONMENTAL MANAGEMENT SYSTEM
Although only raw materials are used in the
process of production, some cardboard production
operations have a negative impact on the
environment. Environmental aspects and their
impact on the environment are identified in each
workshop and division. Obtained information is
collected, analyzed, assessed and then significant
environmental aspects are identified.
In order to reduce the negative impact on
the environment, each year the company
management establishes specific objectives for
improvement of the Company’s environmental
protection and appoints curators in charge of
implementation of such objectives. Curators in
charge of implementation of objectives prepare
plans for implementation of environmental
protection objectives, where measures, actions,
terms and responsibility for implementation thereof
are provided for. Curators prepare half-year reports
on the implementation of objectives and report to
the general director during management review.
ENVIRONMENTAL PERMIT
According to the activity carried out, the
Company must have an integrated pollution
prevention and control permit (IPPC).
IPPC permit was issued on 21 December
2005. The permit of 19 November 2007 has been
renewed, with an effective date from 1 January
2008.
The permit has been corrected on 19
November 2009, on 22 January 2010.
IPPC permit has been approved by the
Environment Quality Division of Klaipėda City
Municipality Administration.
Following the IPPC permit, the Company
executes the control of wastewater and surface
water, the control of stationary sources of air
Evironmental report 2010
-4-
pollution, and performs the monitoring of ground
water.
ENVIRONMENTAL ASPECTS
Water consumption
The company consumes large quantities of
water in the production process.
Tfe fresh water is taken from Curonian
Lagoon and used in the paper machine for low
and high pressure sprays in pressfelts, for web
trim cut jets, for bottom and top wires cleaning
sprays, for condensate cooling.
The company is continuously looking for
ways to use natural resources in a more rational
manner.
In May 2002 a new floater for cleaning
white water from BM was installed. After
treatment he clarrified white water was reused
Water consumption, t.m 3
for more technological purposes and we can to
save fresh water from Curonian Lagoon well.
In 2003 on the board mashine was
installed the new high pressure oscillating
sprays system for forming wires and pressfelts.
After the modernization of waste paper
pulp fine screening department in 2004 the
closed
circulating water system has been
renovated as well. Circling water cleaned in
floater is used in sprayers system with
maximum efficiency.
Water consumption
m3/t production
increased by reduced amounts of production in
2009.
Water consumption per ton
production, m 3
2733
3000
2500
1863
2000
1500
1000
1031
808 759 724 769
637 608 764
500
0
2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
70
60
50
40
30
20
10
0
59
32
15
10
9
8
7,8 7,3
8,7 8,0
2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
Consumption of electric energy and steam
condensate, pulp lines were insulated.
The main user of energy is board machine
with large flow of pulp and water, specifical
dewatering elements for formed paper web and
drying cylinders to dry the paper. Here are a lot of
big vacuum pumps, stock and water pumps which
use electric energy and a lot of drying cylinders
which use steam.
The big consumption of electric energy is
used to prepare recycled pulp in the pulp
preparation plant.
In 2002 was started a new full automatizated
boiler house with two boilers firm Viessmann. Boiler
house is maintained by Company “Ukmergės
energija”.
They are more ecological, more saving and
more efficiently as old boilers. As fuel is used gas.
For saving electric energy and steam in the
company were mounted regulators of power,
special sinchronical motors for compensation
reactive power and frequency converters or stock
pumps. Some old vacuum pumps were changed
into the new more effective pumps and the steam,
AB „Klaipedos kartonas“
After modernization and transfer of waste
paper pulp fine screening department to cardboard
production engine-room in 2004 the energy
consumption for 1 ton of production has been
decreased.
In 2005, the renovation of the transformer plant in
the process water pump house; of the cardboard
department stock preparation department was
completed, including replacement of the old lamps
with new and more efficient ones.
To improve energy resources monitoring,
potable water accounting system was installed in
the stock preparation department in 2005.
In order to reduce consumption of electrical
power in 2006, 5 electric motors were replaced by
the more efficient ones.
In 2005-2006 repair of insulation of all the
pipelines (steam, condensate, water supply) in the
trestlework was carried out, new insulation was
installed on the containers of accumulative
wastepaper mass.
Evironmental report 2010
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In 2005 to 2006, KGM heat ventilation
recuperation systems were renovated in the
company. Through a more efficient utilisation of
the humid-hot air heat released from the drying
oven, the process of drying of paper belt has been
enhanced in the drying room, steam consumption
reduced by heating the air supplied to the room.
By virtue of these renovations an economy of
heat and electric power has been reached and
consumption of gas has been reduced. It was
calculated that CO2 release into the atmosphere
would decrease by 43 tons.
Reconstructed steam heads and siphons
Picture of a boiler
In 2007, 23 steam heads and siphons of the
upper cylinders of the drying groups of cardboard
workshops No. 1 and No. 2 have been
reconstructed into stationary ones.
In 2010 the fourdrinive drive was streamlined,
realized all measures for electric energy saving in
vacuum pump system. Outleys of Electro energy
decreased
2 kWh for 1 t of production
manufacture.
Consumption rates of water, electricity and
steam for production of 1 ton of product conform to
the parameters of the best available techniques
(BAT) in the paper industry.
Wastewater
Wastewater of the company is treated in the
biological wastewater treatment facility. Sludge
generated in this process is stored in 24 fields.
3 types of wastewater are generated in the
company: household, surface (storm water) and
productions. All wastewater is treated in the waste
water treatment facility constructed 14 km away
from Klaipeda.
In
2002-2003,
mechanical
treatment
equipment has been reconstructed and biological
treatment introduced. This enabled to treat
wastewater in accordance to environmental
requirements and to reduce significantly pollution
to the Curonian lagoon.
In order to ensure a stable and reliable
operation of wastewater lines, preventive repair
works of the pressure wastewater line were
accomplished for 480 000 LTL in 2007.
In order to improve the operation of
the aerotank, worn diffusers are constantly
replaced in NVC; part of the diffusers is fixed.
The effectiveness of cleaning sinking materials
in waste water was 96% in 2005 - 2010, BDS7 –
99 %.
The
Company’s
wastewater
treatment
indicators conform to the parameters of the best
available techniques (BAT) in the paper industry.
SM pollution pe r ton
production
0,25
0,20
0,15
0,10
The biological cleaning equipment has been rebuilt in
2004 and primary decanter has been connected to reach
the stability of waste water cleaning process. In 2005,
the effluent collection chamber in Dumpiai was
renovated.
AB „Klaipedos kartonas“
0,05
0,03
0,00
2004
0,02
0,03
0,02
2005
2006
2007
SM fact.
BAT min
0,02
2008
0,02
2009
0,01
2010
BAT max
Evironmental report 2010
-6-
0,20
0,15
0,10
BDS7 pollution per ton
production
0,10
0,09
0,08
2005
2006
0,08
0,06
0,07
0,07
2007 2008
2009
2010
0,05
0,00
2004
BDS7 fact.
BAT min
BAT max
Use of chemical agents
Variety of chemical agents, substances
and preparations are used in the paperboard
manufacturing process including starch, glue,
dyestuffs - which give required mechanical
properties to the cardboard.
Other chemical substances – coagulants,
flocculants, fertilizers, antiseptic substances – are
used for wastewater treatment, for flushing of
piping and equipment, and for reduction of odours.
All the chemical substances are used
according to the approved and authorised
technological regulations, process procedures and
operating instructions in compliance with the
requirements referred to in Safety Data sheets.
A new automatic flocculant dosage equipment of
the firm Kemira was launched into operation in
November 2006
Emissions into air
In 2005-2006, at the initiative of the company,
Klaipėda Public Health Centre (KVSC) made
identification and monitoring of air pollutants in the
ambient air and working environment.
At the end of 2006, stocktaking of the
company’s air pollutant emissions was performed.
It was determined that such pollutants include
ethanol, hydrogen sulphide, acrolein, acetic acid,
ammoniac, formaldehyde, solid particles and other
Consumtion of chemical substance
compounds into ambient air are emitted.
2010
3,0% 4,2%
The company has actively worked in the
0,4%
0,7%
area of solution of the issues related to odour
14,8%
formation and reduction.
Various chemical
73,9%
methods were applied, cooperation with related
3,0%
foreign companies developed.
The Buckman
company
equipment
for
dosage
of chemicals
Starch
Glue
designed
for
odour
reduction
was
installed and
Coagulants
Flocculants
Dyestuffs
Antiseptic substances launched in June 2006. Thus, the odour problems
Other chemical substances
are being successfully solved in the company.
Consum tion of chem ical
substance per ton production
70,0
65,0
60,0
55,0
50,0
45,0
62,6
2006
64,1
2007
60,4
2008
50,0
50,5
2009
2010
The company successfully applies organizational
and technical measures that enable reduction of
chemical impact on humans and environment.
The Buckman company equipment for dosage of
chemicals
In 2008 stocktaking of the company’s air
pollutant emissions was performed newly.
AB „Klaipedos kartonas“
Evironmental report 2010
-7-
The Company's laboratory performs the
monitoring of air pollutants emitted to the
environment according to the approved program.
In 2007, a new device was purchased – a
gas analyzer for measurement of air pollution.
Waste drying equipment Vanex in waste paper fine
screening department
WASTE
Waste handling is of a great importance
for the company. All waste is sorted with the aim
to recycle it.
Waste categories
8000
787
617
7000
731
504
395
quantity,t
6000
5000
4789
716
18
3961
2786
16
929
6183
6589
1667
26
30
2005
323
2006
370
2007
4566
5618
4105
50
2000
1000
437
5240
4000
3000
In November 2005 the dewatering line
(screw press, transporters and magnetic separator)
was installed and launched for rejects after waste
paper repulping and coarse screening. Dryness of
the waste disposed increased from 23 % to 50 %.
Costs for the disposed waste decreased. The waste
dewatering process is further being optimized in
order to achieve higher dryness of waste.
0
2003
2004
29
237
2008
5
199
2009
Waste to recovery
Hazardous w aste
Waste to landfills
Sludge
677
761
9
181
2010
Paper sorting w aste in storage
The company has agreements with
specialized companies which have license to
handle hazardous waste.
Paper and cardboard sorting waste makes
about 95 % of all the waste disposed in the dump.
In order to decrease transported amount
of paper and cardboard sorting waste and to
increase the recycling, Vanex waste drying
equipment has been installed in waste-paper fine
screening department in 2004.
AB „Klaipedos kartonas“
Dewatering equipment in waste paper repulping
and coarse screening department
The company is actively developing sorting
methods of waste paper and cardboard, and ways
of usage of sewage sludge; further researches are
carried out to find the most suitable methods of
wastepaper recycling process waste handling.
It was suggested to use waste paper and
cardboard sorting waste in production of concrete
blocks and thermo insulation boards; sewage
sludge could be used in production of ceramic
blocks and bricks.
The decisions were not
accepted due to lack of economic ground.
In 2005 a laboratory-based experiment of
compost produced from silt and wastepaper
Evironmental report 2010
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grading waste was conducted in cooperation with
the Lithuanian Institute of Agriculture.
In 2006 production tests were conducted
at the company “Medienos plaušas”, by using fine
size sorting waste for production of boards.
“Medienos plaušas” refused to use the waste
because of presence of polystyrene admixtures.
Composting of sludge and rejects after
waste-paper fine screening under outdoor
conditions in Dumpiai was commenced in the
summer of 2006 and accomplished at the end of
2007. The Lithuanian Institute of Agriculture
assessed samples of the compost good. Since
2009 sludge and rejects after fine screening are
compposting in the handling yard in Dumpiai.
The waste generated by the company
were offered for use in production of UAB
“Tauragės keramika” brick composition, by
replacing currently used sawdust with fine
screening waste products.
Samples of waste have been presented to road
constructors – “Lemninkainen”, “Šiaulių keliai”, and
to the producer of insulation materials “Ekorem”.
In 2007, a study on the rough cutting of
rejects after waste paper coarse screening was
conducted, planning to incinerate it when a
regional thermofication boiler-house is built.
During the opening new Klaipeda dump in
2007 was demonstrated the process for covering
the surface of dump by film of fine screening
waste and special polimers. At 2008 the study for
using this film in the dump with UAB “Švaros
investicijos” was finished but decision was not
taking.
In 2008 th was signed on the intention
protocol and in 2009 - preliminary contract with
UAB “Fortum Klaipeda” for supplying the
production waste of our mill (course screening) in
the new cogeneration power station in 2013. For
this purpose were prepared all environmental
procedural for pressing and handling the bales of
recycled pulp rejects. The contract for pressing the
bales was signed with UAB „Švaros diena“. Since
2010 March course screaning waste are pressed
and storaged in Dumpiai; therefore quantity of
waste, wich are carried forward, decreased
signally.
The sewage sludge is stored in the yard.
However, such handling of sewage sludge does not
meet the requirements of the company.
Based on Swedish experience, in June
2005 in Dumpiai cultivation of fast growing willows
for power facilities was begun. The willow
plantation site is fertilized with silt thereby
solving its removal problem. Willows as wood fuel
(biofuel) is suitable for use in heat supply boiler
houses.
Two experimental lots (0,75 and 0,8 ha)
were planted and are cultivated in 2005-2006.
At the end of 2006, a long-term contract
was concluded for planting of 10 ha area with
willows, for fertilization using the wastewater
treatment sludge. In 2007, the sludge was taken
away, spread across the soil and ploughed in. On
springtime 2008 th 5 ha area was planted with
willows.
In 2010 all willows were fertilizied, which
were planted in 2005-2006 like a experimental
consignments.
Willows after 4 months
COMPLAINTS, INCIDENTS
In 2006 (April) two complaints of odour
nuisance from resident citizens were received. An
order from Klaipėda Regional Environment
Protection Department (KRAAD) was given to
perform premature stocktaking of air pollution
sources.
AB „Klaipedos kartonas“
In 2006 occurred one incident causing an
adverse impact on the environment, namely, in
October, during preventive inspection, wastewater
started to ooze through depressurizing valve seal in
the pressurized wastewater line (outside the
company’s limits); repairing works were executed
Evironmental report 2010
-9-
successfully and minimal quantity of wastewater
flowed to the grassland. Wastewater didn’t fall into
watercourse.
The company was ordered to pay money
penalty for the damage caused to the environment.
In October of 2007, at the time of major
repairs, when the wastewater line was being fixed,
an unpleasant odour was felt for some time, in
respect of which the residents expressed their
discontent. According to the data of the Klaipėda
Public Health Centre, the air pollution norms were
not exceeded.
In order to prevent similar situations in the
future, the Plan of Measures for Prevention of
Unpleasant Odours has been prepared and is
implemented.
In 2008, in 2009 and in 2010 complaints from
citizens were not received.
In February of 2010 occurred incident in
wastewater line near wastewater treatment facility.
Wastewater floodet field, where fast growing
willows was providet to plant. Incdent revage was
liquidated, the environmental wasn’t damaged.
OTHER ENVIRONMENTAL MEASURES
Seeking to improve the company’s image in
2005, the head office of the company was
renovated by fully renewing the facade facing
Minijos Street.
nomination The Best Environmental Management
System for the integration of the Company’s
objectives and courses of action in the
environmental protection policy.
Report on stocktaking of ambient air
pollution sources and pollutant emissions, Potential
breakdown hazards and risk analysis, and
Emergency response plan for elimination of possible
accidents were prepared in 2006.
The company is continuously conducting
underground water monitoring in the Effluent
Treatment Plant in Dumpiai.
Based on the
monitoring results, the economic processes have no
impact on the underground hydrosphere.
In June 2006 Helsinki Commission (HELCOM)
deleted AB “Klaipėdos kartonas” of Hot Spots from
the list of the Baltic Sea’s. Reason to delete wastewater treatment efficiency has been improved
and it resulted in compliance with environmental
standarts; modernization of waste water treatment
process for the local area and biological waste
water treatment process is completed; automated
steam boiler-house was built; environmental
management system (ISO 14001) and quality
management system (ISO 9001) have been
introduced.
In 2007, the Company participated in the
competition Achievements in the Environmental the
Company’s objectives and courses of action in the
environmental
protection
policy.
Protection
organized by the Ministry of Environment of the
Republic of Lithuania. The
Company became the winner in
the
In September the Company supported the
international school ecological festival Baltic Week
2007.
In the months of November and December in
2007, in Klaipėda city schools, the Company
organized a waste-paper collection campaign Let’s
Spare Nature, the purpose of which was to enhance
the environmental consciousness of the youth. 42
tons of waste-paper was collected during the
campaign. The same cammpaign was done in
October 2009 – was collected 30 t of waste-paper.
AB „Klaipedos kartonas“
In March 2008 our company was Zone of
Responsible Action named and delivered special
sticker. This fact was published in the newspaper
“Verslo žinios”. The Zone of Responsible Action
Evironmental report 2010
- 10 -
means all personal of company in the all territory
are responsibly behaviouring for sorting and using
the waste of production. We are invited and all
quests our mill to join with this action.
There were the Open Day of company in 13-14
th of May. A lot of citizen, the members from
different agency of municipality, environmental
department and from neighbor companies was
participated two days in the mill. The particular
information about technological processes, answers
of environmental questions and interesting
excursions were represented in this Day.
Engineer-ecologist
Rita Liakstutytė
2011 02
VICISSITUDE…
December of 2010 was cold and harsh. There
were lot of snow in wastewater treatment teritory in
Dumpiai, in willows plantation. Young hind was
noticed, which was looking for food. Therefore after
snowstorm young hind fell down to the wastewater
sump, which is at a depth of 4 meters. The
frightenet hind was rescued by the Animal Care
Crew „Nuaras“. The hind was released to the
freedom.
ENVIRONMENTAL PROGRAMME 2011
The company’s priority objectives in 2011 to decrease fine screaning rejects of reycled pulp
and reduction and saving or energy resources.
When Curonian Lagoon were frozen, there
lived some swans in waswater sump.
AB „Klaipedos kartonas“
Evironmental report 2010
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AB „Klaipedos kartonas“
Evironmental report 2010
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