Investing in the future of corrugated board production

The new production facility offers a fully integrated corrugated board production line equipped with state-of-the-art machinery and technologies. This includes automated production systems as well as advanced solutions for air pollution control and waste disposal. This significant project represents an important step in keeping Opal Fibre Packaging competitive in the global market long-term.

For successful implementation, Opal Fibre Packaging needed partners who could offer not only technical expertise but also customised solutions. Höcker Polytechnik contributed its many years of experience in the development of efficient dedusting and disposal systems.

Technology for efficient dust extraction and waste disposal

The centrepiece of the disposal system is the MultiStar JQ 12/6 filter system with an integrated BrikStar C5 briquetting press and a PMA-U 160 material separator, which is mounted directly above a baling press. Two frequency-controlled clean air fans ensure the extraction performance, while the entire system is operated under negative pressure This minimises the dust load in the disposal centre and the fans offer considerable energy savings thanks to their high level of efficiency.

A central control cabinet monitors the production machines, analyses the incoming signals and ensures that the optimum extraction performance is provided at any time. The system was designed as a ‘hybrid solution’ that utilises both pneumatic conveying and a central conveyor belt. With the help of this the punching waste from further processing is transported to the baling press.

A special dust extraction system with a capacity of 240,000 m³/h was also installed. The MultiStar SL 36/6 filter system and eight frequency-controlled clean air fans ensure efficient air pollution control. A BrikStar C5 briquetting press processes the dust into briquettes, which simplifies handling and disposal.

A total of 700 metres of piping were laid to ensure the smooth transport of dust and waste within the plant. These pipes are equipped with spark extinguishing systems to guarantee the highest safety standards. The installed PHSH 1600 shredder chops production waste and prepares it for further processing.

Logistical challenges and how to overcome them successfully

The realisation of the project confronted the team with particular logistical challenges. The distance between Germany, the headquarters of Höcker Polytechnik and the location of the new production facility in Australia amounts over 16,000 kilometres. In addition, there was a time difference of several hours, which required close and flexible co-operation. Despite this, the tight schedule was kept thanks to careful planning and modern communication technologies.

In addition, Höcker Polytechnik's systems had to be adapted to the strict Australian standards. For example, the main control cabinet and other system components were manufactured in accordance with local requirements. The Höcker Polytechnik team received on-site support from its local partner AFE (Agriculture & Forestry Equipment), which made a significant contribution to the successful commissioning.

Global cooperation and technological excellence

The project in Barnawartha North is an impressive example of how international cooperation, technological excellence and adaptability to local conditions can be brought together Thanks to Höcker Polytechnik's innovative solutions, Opal Fibre Packaging was able to significantly increase its production capacities and at the same time further optimise the efficiency of its production processes.

“This system represents a major advance in corrugated cardboard production. It helps us to increase our efficiency and protect the environment at the same time,” says Rob Bernardin, Maintenance Manager at Opal Fibre Packaging.

Höcker Polytechnik also sees the collaboration as a great success. “We are delighted that our systems not only met Opal's requirements, but even exceeded them,” emphasises Philipp Koch, Project Manager at Höcker Polytechnik. “Despite the logistical challenges, we were able to ensure seamless implementation thanks to intensive planning and close coordination.”

The project is not only a technical milestone, but also a sign of how partnerships between internationally active companies can create sustainable and forward-looking production facilities.