Products and partnerships with the value chain and circularity

Products and patterns of production and consumption that are essential for the sustainable development of society, as well as and lifestyles that value harmony with nature and its resources.

KODS 2030
 

10 benchmarking cases of circular economy in partnership with stakeholders 

 

Number of circular economy cases in partnership with stakeholders

2021 2022 2023  2030 Goal
1 2 3 10
 
 
  1. In the Industrial Bags business, the Ecomix Bag for cement and mortar was developed in partnership with a client in the civil construction sector. The product is made up of 100% dispersible paper that is integrated into the concrete preparation process, thus eliminating the generation of packaging waste. The Ecomix Bag continues to expand Klabin's portfolio, serving both the domestic and foreign markets, due to the environmental benefits offered, meeting the demand for a low-carbon circular economy.
  2. Another project in partnership with a customer is the recycling of Long-Life Packaging (ELV), together with a client in this sector, to increase the installed capacity for recycling the material in the national territory. The recycled fiber, which is of high quality for the manufacture of recycled packaging, is used in the production of recycled paper. The polyal (polyethylene and aluminum) supplies manufacturers of products made from this material.
  3. Another packaging recycling initiative is in partnership with another client in the civil construction sector. The pre-and post-consumer chips generated in the client's operation are collected and returned to the Goiana Unit (PE) for the manufacturing of new packaging that, in turn, will be returned to the client and/or other customers. 

 

Percentage of products covered by Life Cycle Assessments (LCAs)

  Unit 2023 2022 2021 2020
Full LCAs % 100 100 54 57
Simplified LCAs % - - 24 7
Other externally recognized tools % - - - -
Total % 100 100 78 64

 

LCA studies conducted in recent years prove its environmental impact. The ISO 14046 methodology (water footprint) covers the impacts: Abiotic resource depletion, Global warming potential or carbon footprint - Acidification potential - Eutrophication potential - Human toxicity - Photochemical ozone generation potential - Land use - Ionizing radiation - Water depletion, and Particulate matter.

 

SASB-RT-CP-410a.3

Reducing the environmental impact of packaging throughout its life cycle
 

In addition to new investments in reducing emissions, a more renewable energy matrix, such as that observed in 2023, is reflected in a lower amount of CO2eq emitted per ton of product, which in 2023 was approximately 140 kg of CO2eq, resulting in an accumulated reduction of 70% since the initial measurement reported in 2004. 
The products are custom-made to meet the needs of Klabin's customers, utilizing high-tech and complex combinations of virgin and recycled fibers, encouraging the efficient and maximized use of natural resources. combinations of virgin and recycled fibers, encouraging the efficient and maximized use of natural resources. combinations of virgin and recycled fibers, encouraging the efficient and maximized use of natural resources.  combinations of virgin and recycled fibers, encouraging the efficient and maximized use of natural resources. 


Benefits of resource efficiency in the use of products for your customers and consumers

An increasingly efficient utilization of natural resources remains a top priority in Klabin's operations, as it progresses toward a more renewable energy matrix.
In 2023, 92.3% of the Company's energy matrix came from renewable sources, contributing to the reduction of the CO2 footprint for the products manufactured. 
In terms of water use, Klabin achieved a significant reduction of 49% in the water used for the production of 1 ton of product, compared to the base year of 2004. Even so, the Company continues to implement actions to further reduce its water use. 
In the same year, Klabin continued its actions with the Working Group (WG) for Water Management, which has also contributed strongly to the results. The purpose of this task force is to identify opportunities for reducing water intake and consumption in all of Klabin's industrial units. The group consists of a multidisciplinary team that includes representatives from the Pulp, Paper, and Packaging businesses, as well as from the Company's Research and Development, Innovation, and Industrial Environmental Responsibility sectors.
The same behavior is observed in the amount of CO2 equivalent emitted per ton of product, based on the GHG Protocol methodology: Klabin has already recorded a 70% reduction in its specific emissions between 2003 and 2023 (in 2023, emissions totaled about 140kg of CO2eq/t of manufactured product).

 

Product Benefits

    Generated benefits to clients and end-users
PRODUCT BUSINESS Responsible sourcing (FSC certified) Reciclability (rate above 60%) Durability
Celulose de fibra longa - PineCel™ PULP x   x
Celulose de fibra curta - LyptusCel™ PULP x   x
Celulose - PineFluff™ PULP x    
KlaFold® COATED BOARD x   x
KlaFold FZ® COATED BOARD x   x
Klafold GB®
(Grease Barrier)
COATED BOARD x   x
KLAMULTI® COATED BOARD x    
KlaLight® COATED BOARD x   x
KlaLiquid® COATED BOARD x    
KlaCup Natural Kraft® COATED BOARD x    
Klaliner® CONTAINERBOARD x x x
Klaliner White® CONTAINERBOARD x x x
Eukaliner® CONTAINERBOARD x x  
Klaflute® CONTAINERBOARD x x  
Sack Kraft CONTAINERBOARD x x x
KLAFLAT® CONTAINERBOARD x x x
Klasack® CONTAINERBOARD x x x
SHELFLIFE INDUSTRIAL BAGS x x  
CONCEPT INDUSTRIAL BAGS x x  
LINHA SHIELD. INDUSTRIAL BAGS x x x
HARD INDUSTRIAL BAGS x x x
Innovative CORRUGATED BOXES x x  
Concept CORRUGATED BOXES x x  
HARD CORRUGATED BOXES x x x
COLD CORRUGATED BOXES x x x
FRESH CORRUGATED BOXES x x x
UNIQUE CORRUGATED BOXES x x  
ON SITE CORRUGATED BOXES x x  
TOTAL 28      
PRODUCTS AND BENEFITS OFFERED TO CONSUMERS 28      
% 100%      

 

Environmental criteria considered in the development of new products

Criteria  Comment

Choice of raw materials or components with low environmental footprint

Klabin researches new technologies linked to its forest's possibilities such as new uses of wood components (celluloses, hemicelluloses, lignin, or extracts). It has also invested both in the biorefinery (biofuels) line and the development of products based on lignin, wood hemicellulose, and in the application of the cellulose fibers. 

In addition, there is a special line of Recycled Papers produced from pre and post-consumer waste and on modern machines. In the most recent data, in joint work with the packaging sector coalition, 80% of packaging chips and cardboard were recovered (Pöyry, 2022), an important result for reverse logistics. A recent groundbreaking product is the Eukaliner (attached), which is a 100% eucalyptus-based paper. Due to Klabin's high yields for eucalyptus productivity, the need of land use for plantations is ten times smaller when compared to other regular kraft liners. Same volume using less land. 

Direct operations, production & manufacturing Klabin constantly develops products with a lower carbon footprint, increasing the use of renewable sources in the energy matrix, and generating energy from renewable sources such as biomass. In the last 18 years, we have reduced the specific CO2eq / t product emission by 68%. We also seek to adopt methodologies that help map and communicate the carbon footprint of Klabin's products and invested more than BRL 134 thousand in studies in 2022. Besides that, we also have a series of efforts and studies related to our water footprint and carbon footprint of bags, cellulose, eukaliner, and the dispersible bag. The Solid Waste Processing Center, in Ortigueira (Paraná state), is responsible for processing the industrial waste from the Ortigueira and Monte Alegre units, preventing more than 70% of the waste generated from being sent to landfills. Part of it is reused as a byproduct in several applications. The other 29,3% is directed to be recycled and reused in other waste disposal companies  Another example is the EcoLayer bag, developed with a double layer of resin. This solution was aimed at the construction and fertilizer sectors, providing a recyclable condition for the bag, and eliminating plastic while preserving the quality and shelf life of the packaged products. EcoLayer managed the 3rd position in the Eurosack Grand Prix in 2023.
Distribution, storage and transportation Klabin works constantly alongside its clients to improve the mechanical performance (physical protection) of its packaging during the processes of packaging, storage, handling, and transportation. The main goal is to better protect products and avoid waste once the product arrives at the final destination. Projects of remodeling packaging are natural in the company's operations and we have produced benchmarking cases on that matter. One example is the EcoLayer bag, developed with a double layer of resin. This solution was aimed at the construction and fertilizer sectors, providing a recyclable condition for the bag, and eliminating plastic while preserving the quality and shelf life of the packaged products. EcoLayer managed the 3rd position in the Eurosack Grand Prix in 2023.   Another example is the Eukaliner®  a recent development made to reduce paper basis weight by more than 10% while keeping the same final packaging structure (strength). This provides more sustainable packaging while using fewer natural resources and optimized logistics in terms of volume and weight.
Use phase - operation and servicing/ maintenance Klabin works constantly alongside its clients to improve the mechanical performance (physical protection) of its packaging during packaging processes, storage, handling and transportation. The main goal is to better protect products and avoid waste once the product arrives at its final destination. Projects of remodeling packaging are natural in the company's operations, and we have produced benchmarking cases on that matter. One example is the Eukaliner® a recent development made to reduce paper basis weight by more than 10% while keeping the same final packaging structure (strength). This provides more sustainable packaging while using fewer natural resources and optimized logistics in terms of volume and weight.
End of life management
At the end of the life cycle, Klabin's bio-based products can be safely reintegrated into the ecosystem without impact on the environment, restoring part of the energy, water and nutrients once extracted from the soil in the production of pine and eucalyptus forests. Klabin is the first Brazilian company in the pulp and paper industry to have the Belgian OK Compost certification on its cement sacks, which ensures that the paper bag decomposes completely in up to 12 weeks without risk of environmental contamination. Another example is the hydrodispersible cement packaging bags, which is 100% composed of dispersible paper, allowing it to be integrated into the process as the concrete is prepared, thus reducing the amount of waste that goes into the landfill.

 

GRI-3-3 GRI-301-2 GRI-301-3

SASB-RT-CP-430a.1

Percentage of renewable raw materials consumed

  Unit 2023 2022 2021 2020
Total weight of raw materials thousand tons 15,403.99 12,915.12 13,079.12 13,067.40
Weight of renewable raw materials thousand tons 15,150.60 12,637.93 12,820.06 12,852.38
% of renewable raw materials % 98% 98% 98% 98%
% of renewable and recyclable raw materials % 98% 98% 98% 98%

 

Wood represents 95% of the main raw materials used in Klabin's production process.

Material 2023 2022 2021 2020
Non-renewable source materials 9% reduction  7% increase 20% increase 14% reduction
Lime 8% reduction 29% increase 69% increase 24% reduction
Sodium sulfate 9% reduction 1% reduction 143% increase 65% reduction
Caustic soda 11% reduction 3% reduction 8% increase 10% reduction
Pulp 37% reduction 45% increase 33% reduction 26% increase

 

 All of the final products (paper and pulp) have FSC® - Forest Stewardship Council® (FSC-C022516) and Cerflor certifications (recognized by PEFC). This means that the raw materials used in the Company's processes undergo rigorous verification of compliance with forest management and chain-of-custody certification standards to ensure the reliability of our supply chain.
The Company has four recycled paper production units: three located in the southeast and one located in the northeast of Brazil. In 2023, recycled fiber accounted for about 21% of the total weight of corrugated boards and packaging produced. In addition to chips from other plants, Klabin maintains partnerships with wholesale stores of recyclable materials that supply post-consumer trimmings.
Klabin is FSC® Chain of Custody certified in the aforementioned recycled paper plants. One hundred percent of its products use wood or paper fiber as raw material.


GRI-301-1 SASB-RT-CP-430a.1.

Materials used, broken down by weight and volume

Source Material Unit 2023 2022 2021 2020
Renewable Wood for processing thousand tons 14,996.45 12,321.28 12.431,55 12.504,67
  Chips purchased on the market (recycled) thousand tons 129.64 277.75 366,11 217,00
  Purchased pulp (cellulose and CTMP) thousand tons 24.50  38.90 22,40 14,00
  Total thousand tons 13,788.71 12,637.93 12.820,06 12.307,48
Non-renewable Sulfuric acid thousand tons 39.98  38.46 40,69 42,09
  Caustic soda thousand tons 56.96  63.44  65,12 64,77
  Sodium sulfate thousand tons 23.43 25.89 26,22 19,35
  Aluminum sulfate thousand tons 54.81  66.74  59,19 43,10
  Lime thousand tons 55.67  60.81 47,11 93,61
  Kaolin thousand tons 22.53 21.86 20,73 18,76
  Total thousand tons 253.38 277.20 259,05 275,92

In 2023, there was an increase in the number of materials from renewable sources used in the Company. This occurred mainly due to the start-up of PM28, which required more wood for the process. Chips purchased from third parties recorded lower data than in 2022, due to the reduction in packaging demand in the period and excess inventories in the domestic and global market that have formed since the pandemic. The scenario of lower production of certain products in some units was reflected in the reduction in the use of purchased pulp.
About non-renewable materials, there was an overall reduction of 9%. The main factors that influenced this result are related to the temporary reduction in the operation of paper machines in some units. The start-up of PM28 at the Puma Unit, on the other hand, boosted the consumption of kaolin, a product that was not consumed before. The largest reduction recorded was in aluminum sulfate (18%), due to the lower water withdrawal in the period and the stoppage of PM1. Sulfuric acid also dropped by more than 10%. Among the reasons for this reduction are the higher in-house production of acid and variations in production.


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Percentage of recycled fiber used

  Unit 2023 2022 2021 2020
Total weight of wood fiber ton 3,652,479.34 3,542,158.26 3.254.085,93 3.179.573,88
Weight of recycled wood fiber ton 211,239.35 423,527.51 466.711,00 262.722,03
% of recycled fiber % 6% 12% 14% 8%

 


SASB-RT-CP-410a.2

Revenue from products that are reusable, recyclable or biodegradable

Unit 2023 2022 2021 2020
BRL 18,023,479,000 20,033,000,000.00 16,481,000,000.00 11,949,000,000.00


GRI-301-4

Percentage of recycled materials or from sustainable sources

  2023 2022 2021 2020
  % share in products sold Total weight
(in tons)
% recycled or certified material Goal for the year % share in products sold Total weight
(in tons)
% recycled or certified material Goal for the year % share in products sold Total weight
(in tons)
% recycled or certified material Goal for the year % share in products sold Total weight
(in tons)
% recycled or certified material Goal for the year
Wood fiber/paper packaging 97% 14,996,454.26 84% 100% 95% 12,321,277.00 80% 100% 95% 12,431,547.00 88% 75% 96% 12,504,674.00 87% 100%

 

Note: There was an adjustment to the historical amount of wood used in the manufacturing process in the year 2020, prompted by an internal review by the accounting department.


GRI-301-3

Collection of recovered product and packaging data

The percentage of recycled or certified material in 2022 was 8% lower compared to 2021. This fact can be attributed to the Company's expansions, which led to an increase in the consumption of third-party wood. Additionally, strategies have been developed to optimize the forest assets and encourage producers in the region, ensuring a steady supply of certified products to the factories. Currently, Klabin encourages and assists these suppliers in obtaining certification to reduce the number of controlled areas and to continually improve processes. As for the percentage of participation in the products sold in 2022, the production remained stable compared to the previous year.

Percentage of recovered products and packaging for each product category

2023 2022 2021 2020
13% 29% 49% 31%


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Total aluminum purchased

The Company does not purchase aluminum for its processes.


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Recall

There was no recall operation, that is, no Klabin product presented safety risks or non-compliance with current regulations.

Klabin's customers are one of the stakeholder groups that have been driving and challenging the company towards a low-carbon economy. This is reinforced by Klabin's Stakeholder Engagement Policy, which mandates that the company seeks to meet its customers' needs, considering their increasing demands for innovation and sustainability in their products. The theme of Customers and Products is increasingly linked to innovation and sustainability and is considered one of Klabin's Objectives for Sustainable Development (KODS).

Klabin conducts annual satisfaction or perception surveys specific to each of its businesses to identify strengths and opportunities for improvement in products, processes, and operations. Quality, safety, qualification, technical support, and sustainability indicators (including life cycle analysis) are integrated into these surveys. Notably, the annual Cellulose survey, answered by business customers representing approximately 43% of sales volume and 32% of revenue in 2023, resulted in an excellent score of 4.4 out of 5 points (exceeding the target of achieving above 4 points). This survey is conducted annually and has shown the same result for the last three years. 

100% of our products are free from hazardous materials for the environment and human health in their composition. Furthermore, none of our raw materials include minerals and/or other chemicals from conflict regions.

Klabin is the first Brazilian company in the pulp and paper sector to achieve the Belgian OK Compost certification for its cement bags, ensuring that the paper decomposes completely within 12 weeks without environmental contamination risks. Additionally, our packaging is printed with water-based ink and structured with eco-friendly glue that does not contaminate the soil, resulting in a highly biodegradable product reincorporated into the ecosystem within a few months.

Moreover, it's worth mentioning that Klabin's food packaging is certified by ISEGA, AIB, and FSSC 22000, some of the most advanced standards used to ensure the origin of paper for food packaging. These certifications specify prerequisites for producing packaging that guarantees the health of the end consumer, setting standards such as cleanliness and organization of the production area, as well as necessary controls for water, air, and pests in such production.


Circularity at Klabin

 

To develop a business model aimed at addressing the challenges of the linear economy, Klabin has developed a comprehensive approach that aims to promote a Circular Economy broadly. This approach considers how it operates its manufacturing units, how it develops more circular products and materials, the treatment employed for products after their use, and the promotion of circularity in partnership with the value chain.

Klabin's commitment to the circular economy is based on the principles of the Ellen MacArthur Foundation, aiming to eliminate pollution and waste, promote the circularity of products and materials, and regenerate systems.

The year 2023 marked a milestone in the company's evolution on this theme, as Klabin established a specific framework dedicated to it and developed several initiatives. One of these initiatives was the update of the company's public commitment to circularity. Klabin understands that promoting circularity extends beyond its relationship with customers; it is crucial to consider opportunities and foster more circular practices throughout the value chain.

In that year, Klabin also optimized the management process for the circular economy theme, encompassing the following stages:

• Definition of criteria and subdivision into specific classifications for their classification according to the project's objective.
The project evaluation criteria positively consider those that propose to: Eliminate the disposal of 

        
  1. Eliminate the disposal of industrial waste in landfills;
  2.     
  3. Promote materials and products made from by-products of Klabin's industrial operations;
  4.     
  5.  Replace materials of fossil origin in products and processes;
  6.     
  7. Support the structuring of the recycling chain,
  8.     
  9. Promote recycled, recyclable, and/or reusable materials,
  10.     
  11. Promote innovation for the development of products that enable and foster circularity,
  12.     
  13. Promote the Circular Economy in the paper and pulp value chain or other chains.

The classifications of projects submitted to the criteria are:
• Circular industrial operations,
• Innovation and circular products,
• Circularity with customers,
• Engagement with stakeholders.

        
  • Development of a central and systematic database for tracking Circular Economy projects carried out within the Company.
  •     
  • Establishment of a Circular Economy Working Group.

The group consists of 17 members from 12 different areas of the Company. It is led by the Sustainability department and aims to drive collaboration across various departments on the topic, monitor project indicators, address topics that pose risks to Klabin and its clients, and develop opportunities identified in the Circular Economy agenda.

 

Klabin's promotion of circular industrial operations encompasses the use of technology and innovation to ensure that by-products are reused, recycled, reincorporated, or repurposed within the production process. Some examples of circular industrial operations are exemplified in the following cases:

        
  • Drying of Sludge (Puma Unit): Responsible for drying biological and tertiary sludges generated at the Effluent Treatment Stations of the Monte Alegre and Ortigueira factories, with a drying capacity of up to 17,000 tons per month. The dried sludge can be used for energy recovery, acting as renewable fuel in biomass boilers.
  •     
  • SOP Plant (Puma Unit): Potassium is a key ingredient in fertilizer formulations. The SOP plant allows for the production of potassium sulfate from the treatment of ashes generated in the recovery boiler. The production potential is 22 tons of potassium sulfate per day.
  •     
  • Sulfuric Acid Plant (Puma Unit): The first plant of its kind in the Americas installed at a pulp and paper mill. It will produce 150 tons of concentrated acid per day and enable the unit to be self-sufficient in this input. The acid is produced by harnessing sulfur-containing waste gases from the wood cooking process using renewable energy from biomass combustion and black liquor.
  •     
  • Waste Center (Puma Unit and Monte Alegre Unit): Industrial waste such as sludge, ashes, dregs, and wood bark are directed to the Waste Center for the production of agricultural inputs (ecosoil). Part of this product is donated to food producers participating in Klabin's Social Forests program. Some of the foods produced are purchased by Klabin for consumption in the operational unit restaurants and for feeding animals at the Klabin Ecological Park (PEK).

 

The Research and Development department has research lines focused on solutions using renewable materials as alternatives to replace non-renewable products. Some examples of more circular products and materials are exemplified in the following cases:

        
  • Ecomix Bag: an innovative product that enables the elimination of cement bag waste generation. The Ecomix Bag addresses a significant challenge in managing, sorting, and recycling cement bags, while also providing packaging with a negative carbon footprint (carbon capture).
  •     
  • Delivery Packaging: In 2023, iFood launched new paper-based packaging to replace other materials. These packages were produced by Klabin, aiming to support iFood's strategy of eliminating plastic from food transported through the delivery app.
  •     
  • Bag in Box: Klabin developed a paper packaging solution for paints. This innovative solution enabled the reduction of consumption of non-renewable resources.

Updated and verified on: 25/06/2022