MM Gernsbach
Holistic decarbonisation strategy for one of the most
efficient recycled board mills in Europe
May 2025
Project description
Site:
Sector:
Product:
Gernsbach,Germany
Paper and board industry
Recycled board (GT2, GD2)
Capacity:
Machine width:
Grammage:
280.000 t/year
330 cm
250-500 g/m2
Initial situation
The paper facility in Gernsbach operates an established CHP-based energy system that has reliably met its electricity and steam demands to date. As part of ongoing energy management efforts, numerous potential measures to improve efficiency and reduce emissions have been continuously identified. However, a suitable tool was lacking to systematically analyze the complex interactions between production processes, energy supply, and procurement in order to develop an economically viable, long-term decarbonisation strategy and prioritize the appropriate actions. An additional challenge was the heterogeneous data landscape. Without a holistic approach, there was a risk that investments would be delayed or measures evaluated independently, without considering the relevant interdependencies.
About the Gernsbach site
The Gernsbach plant is regarded as one of the most efficient recycled board mills in Europe. The experienced workforce consistently focuses on optimization, quality, and service. Thanks to its geographic location close to customers, logistical processes can also be managed with exceptional flexibility.
Path to Zero approach
With Path to Zero, the site was able to implement a system for the continuous management of its energy strategy.
- The software tool decide models existing equipment, energy flows, and technical options in a digital twin — including the complex interdependencies.
- The market module infom provides the necessary forecasts for developments in the energy and emissions markets.
- The multi-period decision intelligence (MPT) captures intertemporal relationships and derives holistic portfolios of measures on the path to climate neutrality.
- Thanks to the bottom-up model, missing data points of the steam and condensate system could be systematically derived—without implementing an elaborate measurement concept.
“Path to Zero offers a unique combination of tooling and consulting. The software decide enables us to manage complexity and uncover hidden economic potentials. The team’s expertise, the methodological approach, and the practical orientation have allowed us to build a consistent model from a heterogeneous data landscape and align economic and ecological objectives. Moreover, we now have the ability to quickly adapt investment decisions to changing market conditions.”
Konstantin Weber
Energy Manager
MM Gernsbach
Results
Long-term benefits
The energy management team continuously uses the tool decide to evaluate new measures and investments thanks to:
“The data structure with hourly granularity enables us to model performance constraints as well as account for the sharply increasing volatility of energy prices in the optimization. This allows for a holistic approach that leads to optimal solutions. It is especially valuable for us to continue using Path to Zero’s software even after the project has ended. We can flexibly adjust our strategy at any time to new conditions, energy prices, or technical options. Individual measures can also be quickly and systematically evaluated in terms of their economic viability and risk. This saves us significant effort and accelerates decision-making considerably.”
Peter Stieger
Head of Energy Sourcing
MM Group
