A GIANT IN GREEN

In midwest Brazil, Suzano Papel e Celulose – the largest pulp and paper company in Latin America – has brought a new and record-breaking mill to life, fueled by 100% planted eucalyptus trees. The mill transforms wood into pulp and generates surplus electricity for Brazil’s grid. At the heart of this operation is ANDRITZ’s advanced processing technology.

Suzano’s new mill was built from the ground up to maximize efficiency. “A new greenfield project like this lets us apply the best in technology, with a strong focus on sustainability,” says Mauricio Miranda, Suzano’s Director of Engineering, who was responsible for the implementation of the entire project.

Centered around a single fiberline with an annual capacity of 2.55 million tons, the mill is the largest of its kind globally, running on entirely on renewable energy, and producing 180 megawatts of surplus electricity for the national grid.

Just as remarkable is the speed with which the mill has established itself as a reliable high-quality production site. It reached its designed daily production capacity within only 87 days of beginning operations in July 2024, with an excellent 95.3% of final pulp already meeting market-ready quality standards.

Another milestone was met in the beginning of 2025 when the mill’s production reached its first 1 million tons of pulp.

Key to this setup is ANDRITZ’s knowhow and expertise. ANDRITZ supplied the highly resource-efficient pulp mill with leading technologies for fiber production and chemical recovery.

The scope included a complete wood processing plant, the world’s largest single fiberline, a complete pulp drying system, an energy-efficient black liquor evaporation plant, a recovery boiler, a biomass power boiler, and a complete white liquor plant. To further enhance environmental performance, ANDRITZ also supplied gasification plants for fossil-free operation of the lime kilns and a SulfoLoop sulfuric acid plant to recycle sulfur from waste streams and make the mill completely self-sufficient in sulfuric acid.

The new mill is also equipped with one of the most comprehensive automation and digitalization packages in the industry, enabling it to achieve an unprecedented level of autonomy and set a new global benchmark.

UNCONVENTIONAL APPROACH

Building Suzano’s mill was a feat of coordination. Global supply chains were disrupted by the war in Ukraine, delaying shipments. To stay on track, Suzano and ANDRITZ took an unusual step. “We repurposed Suzano’s dedicated pulp ships to transport essential equipment from Asia, keeping the project on schedule,” tells Suzano’s Miranda.

“It was an unconventional approach, but it underscored our team’s and ANDRITZ’s adaptability and commitment to meeting timelines, no matter what external challenges came up.”

The bigger challenge still was getting the right people to the right spot at the right time. Located far from major cities, the mill required a large, qualified workforce – and an even bigger one to construct the plant in the first place. At the peak time of the assembly period, around 11,000 people – comprising the combined workforce of Suzano, ANDRITZ and external personnel from subcontractors – worked on the site. Yet, attracting people to the area proved difficult at the beginning.

“That’s why we’ve invested 75 million reais (approx. 12 million euros) in community infrastructure, including expanding local healthcare and social services,” says  Miranda. The funds paid for new medical facilities, a hospital wing, and social services, addressing local needs. “It truly created a positive impact by bringing jobs and skills training to the area. That’s why the local community has been so supportive, seeing this project as a force for regional development,” adds Miranda.

For Suzano, these investments are as integral to the project’s success as the mill itself, strengthening local infrastructure and supporting the workforce that powers the mill. “These additions weren’t just a regulatory requirement; they were essential for creating a sustainable environment for thousands of workers and residents,” says Miranda.

EQUIPPING THE WORKFORCE

To equip the workforce, Suzano invested in intensive training programs to bring employees up to speed with the mill’s advanced systems. “We used a process simulator for each part of the operation,” explains Miranda. “This process simulator is a crucial factor because it improves the quality of learning.

Our team spent nearly a year in these simulations, learning to optimize performance and anticipate maintenance needs.”

ANDRITZ experts trained Suzano’s operators hands-on, reinforcing critical skills. “It’s one thing to learn in a classroom, but entirely different when you’re simulating real conditions,” Miranda notes. This preparation has enabled Suzano’s team to reach full production efficiency from day one.

RAISING THE BAR ON SUSTAINABILITY

ANDRITZ’s technology is enabling Suzano to achieve an unprecedented level of efficiency. “We’re using proven technologies, but with higher standards and tighter controls,” says Miranda.

This positions Suzano’s mill as a leader in sustainable pulp production, setting a new benchmark for the industry. “By generating all of our own power, we’re self-sufficient and can even send surplus energy to Brazil’s grid,” he adds.

For Miranda, the project represents more than just a single facility. “In my opinion, this is the best way to build a mill like this,” he says. Efficient. Low-emission. Designed to minimize waste. “Our goal is to replicate this model in other regions, especially where sustainable infrastructure is in early stages,” he emphasizes.

“It’s growth, but not at the expense of the environment. This project points to a new way forward, for Suzano and the entire industry.”