Artificial intelligence (AI) is developing rapidly. The massive increase in the power of AI systems and their use in a wide variety of applications offers huge opportunities for science, business and the community. But at the same time, this rapid development poses challenges for the sectors involved.
The maxim ‘Artificial intelligence must be aligned with human values and developed for the benefit of humanity’ is particularly applicable to the field of science. Comprehensive research is more important than ever for understanding and applying technical developments – including ethical, social and legal perspectives. The generation of enormous amounts of data increases the information density of AI systems – while at the same time making interpretation more difficult. The question is whether artificial intelligence the right solution. And what practical potential is there for the technology?
VISION
The goal of the project was to set up an operational and fully automated pilot plant and its digital twin for the production of microfibrillated cellulose (MFC) from beechwood fibres. In the second step, its efficiency was to be improved using fully automated AI. This was intended to provide the industry with important decision-making aids and a practical experience advantage.
The project duration was divided into two stages: The first part was successfully completed in November 2023, and the second funding period concluded in March 2026. 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.
The project’s goal was to build a fully automated pilot plant for the production of microfibrillated cellulose (MFC). In the second phase of the project, the plant’s efficiency was to be improved through the use of a digital twin and AI-based process optimization.
BACKGROUND
Nowadays, many everyday products incorporate ingredients that have been produced from petrochemicals – such as plastics, plasticizers, surfactants, emulsifiers, stabilizers, thickeners and solvents – and are therefore neither sustainable nor environmentally friendly. In the cosmetics segment, these are, for the most part, synthetic polymers or microplastics. Food producers, on the other hand, primarily use emulsifiers and fats based on materials that are highly controversial from a socioecological point of view, including palm oil.
In most cases, however, these ingredients do not have any specific function, such as being an active ingredient or flavor carrier, but only have a secondary role such as thickening or water binding. This makes it desirable to replace them with renewable raw materials. microfibrillated cellulose (MFC) would be one such alternative: It can be produced from locally sourced wood, is safe for humans and animals, and is renewable and biodegradable. However, MFC production volumes have so far remained very low. This can be attributed to several factors such as labor intensity, the enormous investment required to produce each tonne of product, high energy consumption, and the lack of raw material suppliers.
MISSION
To stimulate the use of wood-based microfibrillated cellulose (MFC), 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.
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 MFC.
TARGET GROUPS
The project focuses on two target groups – Germany, as an attractive location for business, and the EU – as both want and have to transition towards a bioeconomy. In most cases, however, newly developed products based on renewable raw materials have to compete economically with established products whose processes have been optimized over decades. But we no longer have the luxury of such a long lead time. That’s why the technology developed in this project is essential in making a pool of experience for AI-assisted product development and process optimization available to companies.
Added to which there is already considerable demand for microfibrillated cellulose on the market. But despite more than 40 years of development, there is still no economically viable security of supply to meet the huge demand. So this project will provide a significant stimulus. It serves the economic and ecological optimization of production plant while at the same time enabling the efficient use of beech wood fibers in keeping with responsible forest management. Forestry operations (as suppliers of raw material), plant manufacturers and operators and users of the microfibrillated cellulose product will all benefit from this increased demand.
TOPICS AND SUBSECTORS
Forestry and wood: The findings from this project will enhance the value that can be created by using wood as a raw material. Wood fibers are used as a raw material source for the production of microfibrillated cellulose (MFC) and will thereby open up new areas of application. 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, microfibrillated cellulose production has been very costly, so it has only been used in very few industries and applications. But cheaper production of microfibrillated cellulose 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.
PROJECT COMPLETION AND CONCLUSION
AI as a Key Enabler of Sustainable Material Production
The KIckBio research project has successfully completed its second project phase, demonstrating that Artificial Intelligence can make the sustainable production of microfibrillated cellulose (MFC) from hardwood more efficient, scalable, and economically viable. The results underline the strong potential for industrial application.
AI-driven recipe optimization: Different AI models were developed, tested, and compared. The findings show that automated recipe optimization is fundamentally feasible. In addition, product quality can be reliably predicted over time, providing a significant advantage for quality assurance and process efficiency.
Digital Twin successfully implemented: A complete Digital Twin of the production plant, including process simulation, was successfully developed. The corresponding process model is now ready for integration into the Celluportal platform, marking an important step toward broader industrial use and digital connectivity.
In-depth process understanding as the foundation for scaling: The comprehensive understanding of process behavior gained throughout the project represents a valuable asset for the future scale-up and industrialization of MFC production. It provides a solid basis for decision-making by future investors and plant operators.
Key learnings for future AI projects: KIckBio has demonstrated that successful AI projects thrive on systematic testing and continuous learning. The project provided ideal conditions for developing and validating AI-driven approaches, creating a valuable knowledge base that future process industry projects can build upon.
“KIckBio has shown us the potential that lies in combining the bioeconomy with Artificial Intelligence. The results represent an important step towards economically viable and sustainable MFC production.”
Dr.-Ing. Wolfgang Wenzel I Project Lead KIckBio, Technikum Laubholz
OUR PROJECT PARTNERS
Through the collaboration with iDIP, ITficient, and Rey Technology, a powerful digital ecosystem was created, integrating plant control, simulation, and Artificial Intelligence. The developed platform enables fully automated production with continuous process optimization.
Together with CADFEM, a highly accurate, real-time Digital Twin of the pilot plant was developed, seamlessly combining simulation, experimental data, and Artificial Intelligence. The results enable precise process predictions and provide the foundation for efficient process optimization.
PTS contributed its expertise in fiber development, enabling the energy-efficient production of high-quality microfibrillated cellulose (MFC). Combined with advanced measurement technology and Artificial Intelligence, this opens up new opportunities for sustainable production.
With its expertise in fine grinding technology, NETZSCH laid the foundation for an optimally designed and highly efficient process technology. Together, the partners developed a high-performance and sustainable plant concept for the future.
Pixact’s innovative optical measurement technology enabled online data acquisition during the production process for the first time. The resulting fiber characteristics played a key role in assessing the grinding process and product quality, representing an important step toward automated and efficient digitalization.
PROJECT TIMELINE
AI Meets Bioeconomy: KIckBio Project Reports Successful Outcomes
SWR1 reports on KIckBio: Focus on nanocellulose production
Technikum Laubholz wins Baden-Württemberg Bioeconomy Innovation Award 2024
Start of KIckBio Phase II: Development of AI for Optimizing Nanocellulose Production at Technikum Laubholz
KIckBio-Workshop: Artificial Intelligence
KIckBio Workshop: Are you a Digital Twin?
KIckBio-Workshop: The kick-off was a success!
KIckBio Kick-Off
KIckBio Board
Fabio Battaglini
Geschäftsführer
ISF Industrie-Service Fricktal AG
Head of Advanced Development Digital Engineering
Festo SE & Co. KG
Chief Operations
Officer (COO)
Felix Schoeller Holding GmbH & Co. KG
About EFRE: The European Regional Development Fund (ERDF) is an EU structural fund that promotes economic, territorial and social cohesion within the EU. Baden-Württemberg’s ERDF-based program focuses on the theme ‘Innovation and Energy Transition’ and specifically supports the research, innovation and carbon emissions reduction. Within the framework of REACT-EU, the Baden-Württemberg ERDF program is receiving additional funds to aid recovery from the coronavirus crisis.
