The project aims to set up an operational and fully automated pilot plant and its digital twin for the production of nanocellulose from beechwood fibres. In the second step, its efficiency is to be improved using fully automated AI. This should provide the industry with important decision-making aids and a practical experience advantage.

The project duration is divided into two stages: The first part was successfully completed in November 2023, with the end of the second funding period following two years later. During the first project stage, the pilot plant was designed, planned, built and put into operation. Particular attention was paid to the full automation of the processing workflows. The aim was to demonstrate the opportunities and challenges involved in this step.

The second project stage for subsequent AI process optimization to increase energy efficiency, supported by a digital twin, has already been taken into account. The approach developed is intended to accelerate the implementation of new processes and materials in the bioeconomy.

To stimulate the use of wood-based nanocellulose, the production plant must have the highest level of automation and state-of-the-art technology to cut costs and development time to a minimum. The aim is to achieve 100% automation throughout the plant. This means that after commissioning, the plant will operate completely autonomously and without human intervention from feed-in of raw materials to the finished product. The plant shuts down when the desired quality of the end product has been reached.

The data obtained from practical application and the digital twin with then be used – with the aid of the AI algorithm – to implement fully automated process optimization. The aim is to demonstrate the challenges and opportunities involved in the planning, construction and operation of a completely fully automated AI-optimized plant and to share findings with the target groups.

This results in a number of benefits: On the one hand, it will demonstrate the steps, costs and opportunities that need to be considered when integrating AI into processing plants. AI-based process optimization will also significantly accelerate the transition to biologically oriented industrial production. And finally, the huge reduction in investment and production costs will result in promoting the broad market success of wood-based nanocellulose.

Forestry and wood: The findings from this project will enhance the value that can be created by using wood as a raw material. The production of nanocellulose will result in wood fiber being used as a raw material source, and nanocellulose, in turn, will find new applications. The pulp industry will be able to market its products to new customers or even commission its own plants for further processing of the specially produced pulp.

Energy: The rising cost of electricity and stricter regulations pose new challenges for power-intensive industries. The innovative technology used in the project – namely the combination of production engineering with future AI – addresses these problems. Basic research on the implementation of Industry 4.0 promotes the use of new technologies – especially in the pulp and paper industries – and has great potential for increasing efficiency.

New materials and surfaces: Until now, nanocellulose production has been very costly, so it has only been used in very few industries and applications. But cheaper production of nanocellulose will allow it to be used in new materials, which means it will not only be the key to product innovations, but also a great potential solution to future issues and challenges.