MM Board & Paper, Austria, has successfully re-started its KM3 board machine at the Frohnleiten mill after ANDRITZ completed a major rebuild. The rebuild included several upgrade measures to improve the machine’s performance in line with the customer’s targets.

Mag. Gernot Schleiss, Managing Director of MM Frohnleiten, explains: “The main objective of our investment was the modernization of the KM3 to enhance the quality of the end product, to reduce specific energy consumption and to increase productivity across the entire product range. We are convinced that ANDRITZ’s innovative PrimeLine technology will help us reach our targets.” Georg-Michael Sautter, ANDRITZ Key Account Manager Paper Board adds: “The new PrimeFlow AT headbox improves the quality of the end product, the two PrimePress X shoe presses lead to energy and bulk savings, and the PrimeRun web stabilizers ensure improved runability. All in all, the perfect package for highly efficient and high-quality production.”  

ANDRITZ PrimeFlow AT headbox – superior flow uniformity with unique, accelerating trapezoidal flow tube. Photo: ANDRITZ

KM3 has a design speed of 800 m/min and a wire width of 5 m. It produces folding boxboard (chromo duplex quality) with 230–450 gsm. The rebuild comprised the modernization of the wire section including approach flow systems, headboxes and hybrid former. In addition, ANDRITZ’s scope included a new press section, the rebuild of the pre-dryer section, an upgrade of two under-machine pulpers, machine clothing and roll covers, adaption of the automation system, as well as assembly, start-up and production assistance.

MM Board & Paper is Europe's largest board producer (excl. liquid packaging board). With a capacity of 540,000 t/y, the mill in Frohnleiten, Austria, is Europe’s largest recycled cartonboard mill.

ANDRITZ GROUP

International technology group ANDRITZ offers a broad portfolio of innovative plants, equipment, systems, services and digital solutions for a wide range of industries and end markets. Sustainability is an integral part of the company’s business strategy and corporate culture. With its extensive portfolio of sustainable products and solutions, ANDRITZ aims to make the greatest possible contribution to a sustainable future and help its customers achieve their sustainability goals. ANDRITZ is a global market leader in all four of its business areas – Pulp & Paper, Metals, Hydro and Separation. Technological leadership and global presence are cornerstones of the group’s strategy, which is focused on long-term profitable growth. The publicly listed group has around 29,100 employees and over 280 locations in more than 40 countries.

ANDRITZ PULP & PAPER

ANDRITZ Pulp & Paper provides sustainable technology, automation, and service solutions for the production of all types of pulp, paper, board and tissue. The technologies and services focus on increased production efficiency, lower overall operating costs as well as innovative decarbonization strategies and autonomous plant operation.

The product portfolio also includes boilers for power generation, flue gas cleaning systems, various nonwoven technologies, and panelboard (MDF) production systems. With waste-to-value recycling, shredding and energy solutions, waste and by-product streams from production are converted into valuable secondary raw materials as well as into sustainable resources for energy generation. State-of-the-art IIoT technologies as part of Metris digitalization solutions complete the comprehensive product offering.

International technology group ANDRITZ has received an order from Hubei Xianhe New Materials Co., Ltd. to supply a chemi-thermomechanical pulping line with a capacity of 350 admt/d for its mill in Jingzhou City, Hubei Province, China.

ANDRITZ’s scope of supply comprises the entire key equipment and supervision service for the mechanical installation, commissioning, start-up, and training.

With this contract ANDRITZ is consolidating its strong market position for low-energy hard wood mechanical pulping technology focusing on production of high-quality fibers at lowest operating cost.

ANDRITZ MSD Impressafiner with highest impregnation efficiency © ANDRITZ

Established in 2021, Hubei Xianhe New Materials is active in several business fields including the pulp and paper industry.

ANDRITZ GROUP
International technology group ANDRITZ offers a broad portfolio of innovative plants, equipment, systems, services and digital solutions for a wide range of industries and end markets. Sustainability is an integral part of the company’s business strategy and corporate culture. With its extensive portfolio of sustainable products and solutions, ANDRITZ aims to make the greatest possible contribution to a sustainable future and help its customers achieve their sustainability goals. ANDRITZ is a global market leader in all four of its business areas – Pulp & Paper, Metals, Hydro and Separation. Technological leadership and global presence are cornerstones of the group’s strategy, which is focused on long-term profitable growth. The publicly listed group has around 29,100 employees and over 280 locations in more than 40 countries.

ANDRITZ PULP & PAPER
ANDRITZ Pulp & Paper provides sustainable technology, automation, and service solutions for the production of all types of pulp, paper, board and tissue. The technologies and services focus on increased production efficiency, lower overall operating costs as well as innovative decarbonization strategies and autonomous plant operation.

The product portfolio also includes boilers for power generation, flue gas cleaning systems, various nonwoven technologies, and panelboard (MDF) production systems. With waste-to-value recycling, shredding and energy solutions, waste and by-product streams from production are converted into valuable secondary raw materials as well as into sustainable resources for energy generation. State-of-the-art IIoT technologies as part of Metris digitalization solutions complete the comprehensive product offering.

German device manufacturer emtec Electronic GmbH presents an inventive product line of specialized testing and measuring equipment at the renowned TAPPICon convention for pulp, paper and cardboard professionals from April 22-26, 2023 in Atlanta, Georgia.

Leipzig, Germany, 08.03.2023 – The demand for paper products remains significant even in the digital age, with the global pulp and paper industry expected to reach a value of roughly 373 billion U.S. dollars by 2029, according to market analyst Statista. Yet consumer preferences are also changing, with a greater focus on sustainable and socially responsible products. At the same time, manufacturers are increasingly on the lookout for new technologies to streamline production costs without negatively affecting quality.

The adoption of “smart” manufacturing technologies and techniques will be a major focal point of this year’s TAPPICon convention, which takes place in April at the Cobb Galleria Centre in Atlanta, GA. At the event, one of Europe's leading manufacturers of testing and measuring devices, emtec Electronic, will partner with Technidyne of Industrial Physics to demonstrate a line of innovative digital products geared toward achieving product and process optimization while reducing operating costs.

These include, for example, the testing duo CAS touch! Charge Analyzing System and FPA touch! Fiber Potential Analyzer, which is able to quickly and reliably determine the cationic demand of the pulp and zeta potential of fibers in the wet end, allowing technicians to administer the correct dosage of additives and thereby reduce resource waste. The result is a higher quality product, produced using fewer resources and lower energy costs, which leads to a quick return-on-investment (ROI).

Other products on display include the TSA Tissue Softness Analyzer, which has been reviewed in TAPPI TIP (Technical Information Paper) 0808-07 and has since become an industry standard for the objective softness measurement of tissue and hygiene products. In addition, the EST Surface & Sizing Tester helps predict the gluability, printability and coatability of paper and board by measuring the converting-relevant parameters surface sizing (surface hydrophobicity) and surface pore structure. As the need for robust paper packaging increases, improvements along these parameters result in a higher quality that can quickly become a unique selling point for a particular product.

Visitors to the TAPPICon are encouraged to learn more about the benefits and measuring principles behind the emtec devices and discuss new ideas with Alexander Grüner (emtec Electronic) by visiting the emtec/Technidyne Booth No. 1020.

About emtec Electronic

Emtec Electronic GmbH develops, produces and distributes worldwide testing and measuring devices for the detection of relevant processing properties of paper, board, nonwoven and textile materials. The portable measuring devices enable manufacturers and converters of paper, nonwoven and textile products for example, to control and optimize the manufacturing and converting processes during ongoing production. From the wet end to the final product, the application of the devices enables an efficient process to achieve and ensure the best possible quality with the least possible effort.

For 27 years, we have relied on innovative, highly specialized measuring instruments combined with a high degree of service orientation. Since the company was founded, we have been intensively involved in scientific cooperation with institutes and companies, further developing instruments for our customers and offering a broad network in over 80 countries from our Leipzig location.

For more information about emtec Electronic, please visit the website:

www.emtec-electronic.de

International technology group ANDRITZ has received an order from Klingele Paper & Packaging Group in Nova Campina, Brazil, to supply automated threading systems for paper machines PM1 and PM3 producing various paper packaging grades. The systems will be installed in 2023.

With an increased focus on safety and reducing paper break time, Klingele Paper aims to automate the tail threading process in the press and reel sections. ANDRITZ developed a threading solution for both machines that will fully automate the process to increase the safety for the operators and decrease the web break time to gain a higher productivity.

As a leading supplier of threading technology, ANDRITZ offers safe solutions that keep operators away from the machine and reduce total threading time.

Klingele Paper & Packaging Group, Nova Campina, Brazil

With its headquarters in Remshalden, the Klingele Paper and Packaging Group is one of Germany’s largest manufacturers of corrugated raw paper cardboard and packaging made from corrugated cardboard.

ANDRITZ GROUP

International technology group ANDRITZ offers a broad portfolio of innovative plants, equipment, systems, services and digital solutions for a wide range of industries and end markets. ANDRITZ is a global market leader in all four of its business areas – Pulp & Paper, Metals, Hydro, and Separation. Technological leadership, global presence and sustainability are the cornerstones of the group’s strategy, which is focused on long-term profitable growth. The publicly listed group has around 27,900 employees and over 280 locations in more than 40 countries.

ANDRITZ PULP & PAPER

ANDRITZ Pulp & Paper provides sustainable technology, automation, and service solutions for the production of all types of pulp, paper, board and tissue. The technologies and services focus on maximum utilization of raw materials, increased production efficiency, lower overall operating costs as well as innovative decarbonization strategies and autonomous plant operation. Boilers for power generation, flue gas cleaning systems, various nonwoven technologies, panelboard (MDF) production systems, as well as recycling and shredding solutions for numerous waste materials also form a part of this business area. State-of-the-art IIoT technologies as part of Metris digitalization solutions complete the comprehensive product offering.

Visy Paper will install a FibreFlow Drum pulping system for its recycled paper mill in Coolaroo, Victoria, Australia.

ANDRITZ will deliver a FibreFlow Drum pulper with a maximum feed capacity of 1,400 t/d, various fiber cleaning equipment, and a spray water treatment system for the production of various board grades.

“The drum pulper is the first of its kind in Australia,” says Jean Yves Nouaze, Executive General Manager Pulp & Paper, Visy. “This upgrade will increase our capacity to process up to an additional 95,000 tonnes of wastepaper per year, to be made into new products here in Victoria. We thank ANDRITZ for partnering with Visy and working collaboratively on this critical project.”

ANDRITZ FibreFlow Drum pulper is perfectly suitable for handling raw material with high reject content © ANDRITZ

Peter Clewes, Vice President Fiber, ANDRITZ Paper, Fiber and Recycling division continues, “I’m very pleased that our first FibreFlow Drum pulping system for Australia is part of an investment that focuses on the further strengthening of the Australian waste and recycling infrastructure.”

The innovative ANDRITZ drum pulping system enables Visy Paper to process a demanding special raw material mix consisting of household wastepaper and Australian OCC (Old Corrugated Containers) with a reject content of up to 25%. The project features the following technological highlights:

• FibreFlow Drum with longer and reinforced design to ensure gentle pulping of the demanding raw material mix and efficient removal of coarse contaminants at minimum fiber loss
• Innovative PrimeScreen X for spray water treatment
• New RB450 cleaner to enable superior removal of glass fragments  

Visy paper mill in Coolaroo is part of the Visy Group – a global leader in packaging and resource recovery – and produces plasterboard liner for the building industry as well as white and brown liner grades from 100% recycled content.

ANDRITZ GROUP
International technology group ANDRITZ offers a broad portfolio of innovative plants, equipment, systems and services for the pulp and paper industry, the hydropower sector, the metals processing and forming industry, pumps, solid/liquid separation in the municipal and industrial sectors, as well as animal feed and biomass pelleting. Plants for power generation, flue gas cleaning, recycling, and the production of nonwovens and panelboard complete the global product and service offering. Innovative products and services in the industrial digitalization sector are offered under the brand name Metris and help customers to make their plants more user-friendly, efficient and profitable. The publicly listed group has around 27,900 employees and more than 280 locations in over 40 countries.

ANDRITZ PULP & PAPER
ANDRITZ Pulp & Paper provides equipment, systems, complete plants and services for the production of all types of pulp, paper, board and tissue. The technologies and services focus on maximum utilization of raw materials, increased production efficiency and sustainability as well as lower overall operating costs. Boilers for power generation, flue gas cleaning systems, plants for the production of nonwovens and panelboard (MDF), as well as recycling and shredding solutions for various waste materials also form a part of this business area. State-of-the-art IIoT technologies as part of Metris digitalization solutions complete the comprehensive product offering.

International technology group ANDRITZ has successfully delivered, installed and commissioned an energy efficient LimeCool system at Stora Enso’s pulp mill located in Imatra, Finland. The start-up took place at the end of 2022.

The innovative ANDRITZ LimeCool system is designed to use the heat of the processed hot lime in the lime kiln. This enables to achieve higher energy efficiency of the white liquor plant and an increase in the production of high-quality lime when compared to conventional separate satellite coolers.

With more than 50 installations globally, the ANDRITZ LimeCool system comprises a stainless-steel integrated structure which is designed for mechanical strength, energy efficiency and easy maintenance. © ANDRITZ

Mika Varis, Project Manager, Stora Enso, says: “We selected the LimeCool system due to the state-of-the-art technology combined with ANDRITZ’s flexibility and fast response. This was the complete package that met our needs.”

This project demonstrates the ongoing solid business relationship between Stora Enso and ANDRITZ. ANDRITZ has just recently supplied production technologies and key process equipment to other Stora Enso locations in Finland and Sweden.

ANDRITZ GROUP

International technology group ANDRITZ offers a broad portfolio of innovative plants, equipment, systems, services and digital solutions for a wide range of industries and end markets. ANDRITZ is a global market leader in all four of its business areas – Pulp & Paper, Metals, Hydro, and Separation. Technological leadership, global presence and sustainability are the cornerstones of the group’s strategy, which is focused on long-term profitable growth. The publicly listed group has around 27,900 employees and over 280 locations in more than 40 countries.

ANDRITZ PULP & PAPER

ANDRITZ Pulp & Paper provides sustainable technology, automation, and service solutions for the production of all types of pulp, paper, board and tissue. The technologies and services focus on maximum utilization of raw materials, increased production efficiency, lower overall operating costs as well as innovative decarbonization strategies and autonomous plant operation. Boilers for power generation, flue gas cleaning systems, various nonwoven technologies, panelboard (MDF) production systems, as well as recycling and shredding solutions for numerous waste materials also form a part of this business area. State-of-the-art IIoT technologies as part of Metris digitalization solutions complete the comprehensive product offering.

In line with its ambition to be a leader in society’s transition to climate neutrality, Södra has laid out its commitment to science-based targets for 2030 in its annual and sustainability report, and to reach net zero by 2040.

The Science Based Target initiative (SBTi) approved Södra’s targets in December 2022 and will provide support in quantifying its emissions and following up emission reductions in a way which is structured, recognised and transparent.

SBTi enables Södra to set its emission-reduction targets in the context of the goals of the 2015 Paris Agreement. Near term, Södra is committed to reducing emissions in line with a global warming limit of 1.5°C, compared with pre-industrial levels, by 2030, which is the scope of the science-based target.

“We are ambitious in our targets and longer-term goals,” said Anders Norén, Director of Sustainability at Södra. “The commitment of the Paris Agreement is to halve scope 1, 2 and 3 greenhouse gas emissions by 2030, with 2020 as the base year, and reach net zero by 2050. Södra’s climate ambition is indeed to halve scope 1, 2 and 3 greenhouse gas (GHG) emissions by 2030 but our goal is to reach net zero by 2040, which is ahead even of Sweden’s target to be the first welfare state to reach net zero by 2045.”

Consistent with the goal of “Fossil-Free Södra"
Science-based targets are consistent with the goal of “Fossil-Free Södra,” the Group’s  programme of current and planned projects for emission reduction, which is the engine driving its climate ambitions.

“Working with customers has always been a defining Södra characteristic, and science-based targets emphasise this vital relationship,” said Anders Norén. “After all, our scope 1 and 2 GHG emissions become our customers’ scope 3 GHG emissions and vice versa. ‘Walking the walk’ is the best contribution we can make to the transition to climate neutrality, supporting, and being supported by, all those in our value chain.

“Our intention is to increase climate benefits all the way from our members’ forests to customers’ products. With this in mind, Södra has committed that 70 percent of customers, by emissions, will have set science-based targets themselves by 2027: almost 35 percent, by emissions, have already done so. With strong support already evident among our customer base, we can look forward to a future with more joined-up thinking when it comes to the transition to a net-zero economy.”

As a large organization, Södra can have a strong impact on climate transition. The group is one of Sweden’s largest buyers of transportation, for example, and intends to continue its leadership in the use of biofuels and electrification of road transport and rail, and to look at all possible measures to decarbonise logistics from its members’ forests to the customer’s gate.

For full details of Södra GHG emissions in 2022, please consult the annual report.

Södra was founded in 1938 on the idea that we are stronger together. We are now the largest forest-owner association in Sweden, with 51,000 family forest owners as members. Together, Södra’s members own a world-leading industry that processes forest raw material into renewable products such as pulp, timber, building systems, liquid bioproducts and energy. About 3,300 people are employed in our forest industry and in 2022, Södra generated sales of SEK 33 billion. Our products are exported all over the world and together, we are contributing to a more natural way of living. Rooted in the forest, we grow the future.

Valmet will supply a coated board machine for Graphic Packaging International (GPI) in the United States. Valmet delivered a similar coated board machine to GPI’s Kalamazoo mill in 2022. The new machine will be supplied to GPI’s mill in Waco, Texas. The start-up of the machine is scheduled for early 2026.

The order is included in Valmet's orders received of the first quarter 2023. Its value will not be disclosed, but an order of this type and scope is typically valued between EUR 140 and 180 million.

With this investment in the latest coated board technology, GPI is committing to sustainable packaging with exceptional product quality and cost competitiveness for producing coated recycled board (CRB) grades.

“Valmet has offered us innovative yet proven technology to reach our high product quality targets. We have had a long and good cooperation with Valmet. Our relationship is based on mutual trust, which is very important in large projects like this one,” says Rusty Miller, Senior Vice President, Engineering and Technology, GPI.

“Valmet has a very good relationship with Graphic Packaging International, and we have had successful projects with them. We are happy to be involved in this important project to provide a state-of-the-art coated board machine for their optimized mill network in the United States,” says Michael Gray, Vice President, Capital business, North America, Valmet.

Technical details about the delivery

Valmet’s delivery for the new coated board machine will include equipment for stock preparation, approach flow systems, board machine with extensive process ventilation scope, a wide Valmet DNA automation package and a winder. The delivery will also include Valmet Industrial Internet services.

The board machine will produce coated recycled board (CRB) grades, in other words white line chip board (WLC) grades, with an annual capacity of approximately 500,000 short tons which corresponds to 456,000 metric tons.

Information about the customer Graphic Packaging International

Graphic Packaging International, headquartered in Atlanta, Georgia, is committed to providing consumer packaging that makes a world of difference. The company is a leading provider of paper-based packaging solutions for a wide variety of products to food, beverage, foodservice, and other consumer products companies. The company’s net sales in 2022 were approximately USD 9 billion. It has over 130 facilities and over 24,000 employees worldwide.

Valmet is a leading global developer and supplier of process technologies, automation and services for the pulp, paper and energy industries. With our automation systems and flow control solutions we serve an even wider base of process industries. Our 17,500 professionals around the world work close to our customers and are committed to moving our customers’ performance forward – every day.

The company has over 220 years of industrial history and a strong track record in continuous improvement and renewal. In 2022, a major milestone was achieved when the flow control company Neles was merged into Valmet. Valmet’s net sales in 2022 were approximately EUR 5.1 billion.

Valmet’s shares are listed on the Nasdaq Helsinki and the head office is in Espoo, Finland.    

Follow us on valmet.com

This month, James Cropper became one of 11 companies to support environmental non-profit Canopy, showing a love for forests by joining the Pack4Good initiative that is focused on transforming paper packaging supply chains and protecting Ancient and Endangered Forests. 

Providing truly sustainable and responsible papers and packaging for customers requires rigorous testing of the fibres used in James Cropper’s operations and tracking the provenance of the supply chain. With the help of the forest mapper from Canopy, James Cropper can ensure that none of its supplies are from at-risk forests and that environments and communities related to the origin of its paper products are safeguarded.  

The scientific community warns that at least 50% of the world’s forests need to be conserved and/or restored by 2030 to ensure global temperature increases stay below 1.5˚C and address the global climate and biodiversity crises. The time is now for companies to show forests some love by taking supply chain leadership. 

Tricia Hartmann, Global Packaging Lead from James Cropper said: “From the world’s first technology to upcycle used coffee cups, to the industry leading incorporation of used jeans into fully recyclable paper for packaging – transforming waste into beautiful paper is at the core of James Cropper’s FibreBlend Upcycled Technology mission. 

“We are proud to be part of Canopy’s Pack4Good initiative alongside so many businesses also dedicated to addressing the growing forest footprint of paper packaging. Solutions exist today such as utilising alternative fibres to make strong, attractive, and versatile packaging, while taking pressure off of forests and developing new regenerative supply chains.”  

Through Pack4Good, James Cropper is among a growing list of brands and packaging suppliers helping to make sustainable paper packaging the norm.  

Innovations such as the Rydal Packaging Collection and eco-designed moulded packaging solution, Colourform, are examples of how James Cropper has been able to deliver game-changing packaging narratives for brands in the beauty, fashion and drinks sectors, and also significantly reduce material use through design innovation. 

There are now 371 companies with Pack4Good policies demonstrating the type of ‘out-of-the-box’ leadership and innovative thinking that will transform supply chains, scale-up sustainable solutions and protect and manage our forests responsibly. 

About James Cropper   

James Cropper is a prestige paper innovator based in the English Lake District, supplying distinct, custom-made paper products to many of the world’s leading luxury brands, art galleries and designers.     

Throughout 176 years of high-quality paper production, the business has been carefully stewarded and nurtured by six generations of the Cropper family and is renowned globally for individual expertise in colour and fibre innovation.       

James Cropper, one of the world’s most innovative papermakers, has appointed Rob Tilsley as Fibre Operations Group Lead.     

Rob’s role will drive growth of upcycled fibre within the company’s paper products to 50% by 2025, both increasing the capacity and the quality of recovered fibre available to the James Cropper business. In addition, he is responsible for the day to day management of the on-site upcycled fibre facility, baler house and waste-water plant; as well as the introduction of new fibre streams and the standardisation of recovered fibre use.  

Rob TilsleyThe appointment comes after the creation of James Cropper’s destination brand for its expertise in fibre. FibreBlend Upcycled Technology is at the heart of the business purpose: Pioneering materials to safeguard our future. The FibreBlend model organises the plethora of fibre blend options available to customers into a clear offer, demonstrating the limitless expertise available to them.  

Rob takes on the role after 18 years’ service at the James Cropper mill in the Lake District, bringing with him deep knowledge of the company’s speciality paper making processes, capabilities and products.  

Richard Burnett, Head of Technology and Innovation at James Cropper said: “Rob’s extensive knowledge of the industry and our business coupled with his commercial mindset and passion for innovation make him the perfect fit to drive our ambitions for FibreBlend Upcycled Technology. 

“At a time when consumer demand for paper and packaging which tirelessly pushes the boundaries of sustainable solutions continues to grow at pace, it is an exciting time to take on this role. FibreBlend Upcycled Technology offers a dedicated team committed to perpetual sustainable fibre innovation; we look forward to drawing on Rob’s experience to help to continue to deliver unrivalled expertise in this area.”

Speaking on his appointment Rob Tilsley said: “From the world’s first technology to upcycle used coffee cups to the industry leading incorporation of used jeans into fully recyclable paper for packaging - transforming waste into beautiful paper and packaging is at the core of the FibreBlend Upcycled Technology mission. Having honed my knowledge of papermaking within the James Cropper family, I am over the moon to be involved in continuing this mission and reaching our goal to have a balance of fresh and recovered fibre across our portfolio of paper products by 2025.” 

About James Cropper    

James Cropper is a prestige paper innovator based in the English Lake District, supplying distinct, custom-made paper products to many of the world’s leading luxury brands, art galleries and designers.    

Throughout 176 years of high-quality paper production, the business has been carefully stewarded and nurtured by six generations of the Cropper family and is renowned globally for individual expertise in colour and fibre innovation.       

CupCycling^TM  

CupCycling^TM is a technology innovated by James Cropper that extracts the polythene lining of disposable coffee cups, enabling them to be recycled and transformed into high-quality paper, packaging and stationery products. By working with retailers such as McDonald’s and Costa, James Cropper has implemented the infrastructure needed to collect single-use waste products and transform them into beautiful papers and packaging for the likes of Selfridges and Lush. Circular design is at the core of CupCycling^TM. To date, James Cropper has recycled over 100 million coffee cups and has capacity to upcycle 500 million cups per year.   

Read more about the CupCycling^TM story here.