Transforming tissue mills with electrification

In tissue making, drying processes consume about 70 percent of the total energy, most of which is provided by fossil fuels. However, it is now possible to replace combustion-based heating processes with electric heating solutions. By integrating high-temperature heat pumps and replacing burners with electric heaters, mills can eliminate fossil fuel combustion from their drying sections, reducing their direct CO2 emissions and energy consumption. For example, by adopting electric heaters in a Yankee Hood air system, mills can reduce energy consumption by up to 10 percent compared with systems using fossil fuel burners.

The advantages of electrification

“Electrifying processes in tissue mills is worthwhile because it directly supports customers’ decarbonization, energy efficiency, and cost predictability targets,” says Claudio Ardrizzi, Energy Management Expert, Tissue Production Processes, Valmet. “Electrification also increases flexibility.

The first step is often to make the invisible, visible – using data to reveal inefficiencies.

As more countries expand renewable electricity generation, mills can increasingly operate on low-carbon power. This means customers are not only reducing emissions today but also future-proofing their operations against carbon pricing, regulatory pressure, and fossil fuel volatility. Electrification isn’t just about replacing one energy source with another – it’s about building a smarter, more controllable, and more sustainable production environment.”

Helping customers save energy

“My degree is in energy engineering, and I use a lot of my education in my work, consulting customers, mainly for the drying section,” Ardrizzi says. “On a daily basis, I help customers understand where their energy is used, where losses occur, and what the improvement potential is. The first step is often to make the invisible, visible – using data to reveal inefficiencies. For example, this involves mapping current energy consumption and identifying electrification opportunities. Once we have a clear picture, we can prioritize actions that bring both sustainability and financial benefits. We can also support customers with implementation and performance monitoring, and train their mill teams in energy optimization practices.”

Simplified scheme of a high-temperature heat pump.

Mill-wide energy efficiency expertise

Valmet supports customers with a mill-wide perspective, combining process technology expertise with deep knowledge of energy systems and automation. “We don’t look at electrification as an isolated upgrade; we analyze the entire mill ecosystem – steam balance, heat recovery, drives, and automation,” Ardrizzi explains. “This includes everything from energy audits and feasibility studies to mill-wide energy balance simulations. We support customers with electrification roadmaps and the integration of electric boilers, heat pumps, and electric heaters.”

I help customers understand where their energy is used, where losses occur, and what the improvement potential is.

“Because Valmet delivers tissue machines, automation, and services, we can optimize across process boundaries. This integrated approach is essential when transitioning to higher electrification levels. Electrification solutions such as electric heating, heat pumps, or hybrid energy systems must always be evaluated in the full tissue mill context.”

On the road to fully electrified mills

The technology required to electrify heating processes has advanced rapidly in recent years, making it a realistic option for tissue mills. “One of the most important developments is the integration of high-efficiency heat pump technology into tissue mills,” Ardrizzi says. “Modern industrial heat pumps can upgrade low-grade waste heat into useful process heat, significantly reducing demand for steam from fossil fuels. Another key trend is hybrid energy systems, where electric boilers, heat pumps, and traditional systems work together optimized by advanced automation. This allows mills to dynamically respond to electricity prices and the availability of renewable power.”

“Over the past few years, interest in electrified heating processes has accelerated significantly, and customers are being more proactive. Electrification is no longer theoretical. We’re seeing real practical steps being taken toward fully electrified mills,” he concludes.