Driving Efficiency in Paper Sizing with Bersize™ ASA Technology

When a leading paper mill struggled with costly downtime and machine cleanliness issues, Aurorium partnered with the team to trial Bersize™ ASA technology. The results delivered not just cleaner operations and improved sizing performance, but also the potential for ~$1M in annual savings. This success reflects Aurorium’s collaborative approach and commitment to helping mills achieve lasting efficiency gains.

Key highlights include:

• Customer Challenge: A high-speed paper machine faced persistent downtime, cleaning costs, and deposit issues.
• Aurorium’s Innovative Solution: Trialed Bersize 7904 and Bersize 7908 to deliver cleaner operation, higher dosing flexibility, and stable emulsification.
• Customer Impact: Reduced downtime, improved efficiency, and potential cost savings of ~$1M annually.
• Future Outlook: Ongoing partnership to eliminate surface sizing and enhance long-term sustainability.

customer challenge

persistent downtime and costly disruptions

A leading paper mill operating a high-speed Valmet® OptiFormer machine faced persistent issues with machine cleanliness and costly unplanned downtime. The mill aimed to optimize sizing performance while reducing reliance on surface sizing agents and minimizing disruptive deposits on transfer belts.

Aurorium’s innovative solution

proactive partnership with tailored ASA solutions

Aurorium collaborated closely with the mill’s production team to design a structured trial program. By introducing Bersize 7904 and Bersize 7908 — both globally supplied, REACH-compliant products — Aurorium demonstrated a commitment to improving performance, reducing downtime, and providing a commercially ready solution.

The trial goals included:

• Improve machine cleanliness and reduce felt contamination
• Enable higher ASA dosages at the wet end
• Reduce or eliminate the surface size used at the film press
• Deliver stable emulsification with lower energy input

trial results  

Aurorium collaborated closely with the mill’s production team to design a structured trial program using Bersize 7904 and Bersize 7908 — both globally supplied, REACH-compliant products.

The trial was carried out in three phases:

1. Bersize 7904: Delivered acceptable sizing but required high energy input.
2. 50/50 Blend of Bersize 7904 and Bersize 7908: Improved stability and emulsification.
3. Bersize 7908: Demonstrated superior performance, ultimately approved for continued use.

proven benefits

• Operational Efficiency: Bersize 7908 enabled longer run times between unplanned shutdowns, reducing downtime and maintenance costs
• Cost Savings: Potential to eliminate surface size at the film press, saving approximately $500K/year. Reduced machine cleaning and belt replacement costs, saving approximately $500K/year
• Technical Differentiation: Superior emulsification technology reduces deposits and achieves optimal sizing

what’s different about Aurorium’s approach?

• Tailored Chemistry: Customized ASA formulations for specific machine needs.
• Collaborative Approach: Close technical engagement with the customer’s production team.
• Innovation in Emulsification: Breakthrough in sizing performance and machine cleanliness compared to incumbent ASA.
• Commercial Readiness: Aurorium’s capacity supports immediate transition to the preferred product. 

customer impact

transformative results with measurable value

The trial proved that Bersize® 7908 not only solved the mill’s immediate operational issues but also created long-term financial and efficiency gains. These improvements positioned the mill for more reliable, sustainable production moving forward.

• Reduced Downtime: Cleaner operations enabled longer continuous production runs, minimizing disruptions.
• Lower Operating Costs: Combined savings of ~$1M/year through reduced belt replacements, cleaning, and surface size usage.
• Enhanced Efficiency: Ability to dose higher ASA levels at the wet end without deposits, unlocking new performance levels.
• Trusted Partnership: Technical engagement and tailored chemistry reinforced Aurorium’s role as a long-term strategic partner.
• Future-Ready Operations: Trial validated a pathway to eliminate surface sizing, supporting sustainability and cost goals.

future outlook

sustained performance and continued partnership

The paper mill plans to continue with Bersize® 7908 for reliable long-term use while working with Aurorium to phase out surface sizing entirely. Together, Aurorium and the customer are exploring new opportunities to further optimize sizing efficiency, reduce resource intensity, and support more sustainable papermaking practices.

Talk to us today to discuss your specific operational needs and discover how we can help you achieve your efficiency goals.