The largest single-line pulp mill in the world pushes the boundaries of sustainable manufacturing by turning wood into pulp and renewable power. ANDRITZ‘s groundbreaking processing technology lies at the center of this operation. With the help of 100% planted eucalyptus trees, Suzano Papel e Celulose, the biggest pulp and paper manufacturer in Latin America, has opened a brand-new, record-breaking mill in midwestern Brazil. In addition to producing excess electricity for Brazil’s grid, the mill turns wood into pulp. Suzano’s new mill was constructed for maximum efficiency. “A new greenfield project like this lets us apply the best in technology, with a strong focus on sustainability,” comments Mauricio Miranda, Suzano’s Director of Engineering, who was responsible for the implementation of the entire project.

In early 2025, the mill achieved a milestone by producing its first 1 million tons of pulp, due to ANDRITZ’s expertise and technologies for fiber production and chemical recovery. The mill, with a 2.55 million tons capacity fiberline, is the largest globally, powered by renewable energy. It quickly met production capacity, with 95.3% high-quality pulp in 87 days from start in July 2024. In early 2025, the mill achieved a milestone by producing its first 1 million tons of pulp, thanks to ANDRITZ’s expertise and technologies for fiber production and chemical recovery. The scope covered a full wood processing and pulp plant, featuring advanced environmental solutions like gasification and recycling. Automation and digitalisation maximize autonomy and set a new industry standard.

Uncommon Method
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,” says 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.”

Getting the right people to the remote mill was a major challenge due to its location. At its peak, around 11,000 workers from various companies struggled to be there initially. “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,” continues Miranda. Suzano sees these investments as crucial to the project’s success, enhancing local infrastructure and supporting the mill’s workforce. “These additions weren’t just a regulatory requirement; they were essential for creating a sustainable environment for thousands of workers and residents,” says Miranda.

Incredible Start-up Curve
Suzano continuously produced bleached kraft pulp in late December 2024 at an average daily rate that was more than the 7,203 t/d target for 30 days. Additionally, ANDRITZ provided a SulfoLoop sulfuric acid factory, which in January 2025 attained full capacity. It allows the mill to become self-sufficient in sulfuric acid and recycle sulfur from side streams.

Setting up the workplace
Suzano made significant investments in training programs to equip the personnel and get them up to speed on the mill’s leading-edge systems. “We used a process simulator for each part of the operation,” describes 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 optimise performance and anticipate maintenance needs.” ANDRITZ experts reinforced critical skills through hands-on training for Suzano’s operators. “It’s one thing to learn in a classroom, but entirely different when you’re simulating real conditions,” Miranda remarks. Suzano’s preparation achieved immediate full production efficiency.

Increasing the Sustainability Bar
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. Suzano’s mill leads in sustainable pulp production, setting an industry benchmark. “By generating all of our power, we’re self-sufficient and can even send surplus energy to Brazil’s grid,” he adds. To Miranda, the project signifies more than a mere facility. “In my opinion, this is the best way to build a mill like this,” he says. Efficient. Low-emission. Designed to minimise waste. “Our goal is to replicate this model in other regions, especially where sustainable infrastructure is in early stages,” he affirms. “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.

Source: andritz.com