Voith’s SteamBooster is revolutionizing production at Koehler Paper in Kehl by converting exhaust heat into useful steam. This innovation, a pillar of clean energy, is already saving up to 1,500 tons of CO2 annually, cutting costs and driving sustainability in the industry.
In a continuous pursuit of more efficient and environmentally responsible processes, Koehler Paper has reached a significant milestone at its Kehl plant in Germany with the implementation of the Voith SteamBooster. This technological innovation lies at the heart of a robust three-stage heat recovery concept designed to optimize energy usage and mitigate the environmental impact of paper production.
In operation since June 2025, the solution stands out for its ability to transform high-temperature waste heat into valuable process steam. The direct result of this collaboration between Voith and Koehler Paper is a remarkable saving of up to 1,500 tons of CO2 annually, highlighting both companies’ commitment to sustainability and clean energy in the industrial sector.
Valuable Energy Recovery and Carbon Emission Reduction
Installed on the SM 8 offline coater, which produces specialty monolithic papers at the Kehl plant, the Voith SteamBooster operates in conjunction with non-contact MCB dryers. Previously, the coating process generated exhaust heat reaching temperatures of up to 300°C, and much of this energy was simply wasted into the atmosphere.
With the new configuration, hot exhaust air from the dryers is now channeled through a heat exchanger. This ingenious system generates steam from condensate, which is then reintroduced into the plant’s production processes. The turnkey solution is capable of generating approximately one ton of steam per hour, easing the load on boilers and resulting in a substantial reduction in operational costs and carbon emissions.
Proven Technology in a New Application for Heat Recovery
The technology behind the SteamBooster, initially patented by Voith to recover energy from tissue machine hoods, demonstrates its versatility by being successfully adapted for all types of paper machines. Its applicability extends to any machine with exhaust air temperatures above 100°C, originating from either hot air dryers or vacuum blowers, opening a wide range of possibilities for the paper industry.
Installation of the system is notably simplified and can be integrated into existing machines during scheduled maintenance shutdowns or included in new installations. For a medium-sized paper mill, the SteamBooster can recover between one and five tons of steam per hour, depending on the specific configuration, with an impressive return on investment that can be less than two years, making it an economically attractive option for pursuing energy efficiency.
Decarbonizing Industrial Processes with Voith Innovations
In Kehl, the long-standing partnership between Voith and Koehler Paper has resulted in the creation of one of the world’s most efficient specialty paper production lines. The success of the SteamBooster implementation underscores the potential paper manufacturers have to save energy and significantly reduce their CO2 emissions by intelligently recovering and reusing high-temperature waste heat from their production processes.
Faced with increasing pressure to decarbonize energy-intensive operations, Voith has been investing in the development of a comprehensive portfolio. This includes heat recovery systems, thermal electrification technology, services, and digital solutions. Designed for straightforward implementation, this suite of offerings aims to assist paper manufacturers in substantially reducing both energy consumption and carbon emissions, moving toward a more sustainable future.
Dr. Mario Vollmer, Head of Energy Innovation at Koehler Group, stated:
We are impressed by the quick and simple installation of the SteamBooster. As we expected from our long-term partnership with Voith, the entire process was smooth and generated valuable energy efficiency gains for our plant.
The journey toward decarbonization with Voith is structured. It begins with a detailed conceptual study and encompasses the complete delivery and integration of the most suitable electrification and heat recovery systems for the site’s specific conditions and production goals. This close collaboration ensures that the entire process, from planning to execution and service, is managed by a single supplier, ensuring cohesion and effectiveness.
Martin Dauner, Product Manager Steam & Condensate at Voith Paper, explained:
The SteamBooster is a low-risk, high-return turnkey solution that substantially reduces energy consumption and carbon emissions. The technology is tailored to site conditions. It is simple to install during regular maintenance shutdowns. As multiple installations demonstrate, a typical paper mill can expect a return on investment of less than two years.
The successful implementation of the SteamBooster at Koehler Paper’s Kehl plant not only reiterates the technical and economic viability of heat recovery as an energy efficiency strategy but also paves the way for a more sustainable paper industry. With an annual reduction of up to 1,500 tons of CO2, the initiative serves as a model for other operations looking to decarbonize their energy-intensive processes.
This collaboration between Voith and Koehler Paper reinforces the importance of innovation and partnership in addressing global environmental challenges. By focusing on clean and sustainable energy solutions, Voith continues to position itself as a leader in industrial transformation, offering technologies that promote a greener future for paper production worldwide.