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Situated 50km south of the port of Durban in the province of KwaZulu-Natal (South Africa), Sappi Chemical Cellulose's Saiccor Mill has the capacity to produce approximately 800,000 tons of Elemental Chlorine Free (ECF) chemical cellulose (dissolving pulp) per annum - the world's largest manufacturer. We export almost all of the product that is produced at Saiccor Mill.
Chemical cellulose, a product made from wood, mostly from our plantations, is sold to converters for a wide range of consumer products, such as clothing, cellular phone screens, cellophane wrap for sweets and flowers, pharmaceutical and household products, and make-up such as lipstick.
Unlike many synthetic raw materials, the product supplied by Sappi Chemical Cellulose is produced from a natural and renewable resource. The mill’s timber consumption is comprised primarily of Eucalyptus hardwoods. These fast growing trees are grown in relatively close proximity to the mill, which contributes to the business’ position as a low cost producer of chemical cellulose.
At Sappi Chemical Cellulose we produce a world-class product in a country where technology and infrastructure meet the demands of the international community.
Our products
The performance of Sappi Chemical Cellulose pulp is determined in the process - it is possible to specifically tailor a range of different properties to best suit a given application. The most commonly adjusted property is the pulp purity. Sappi Chemical Cellulose can supply a range from 91% alpha to 96% alpha, depending on customer requirements.
Product areas using chemical cellulose include:
Acetate
- Acetate flake is used in products such as high-quality yarns and fabrics.
- Acetate tow is used in cigarette filters, as well as in high-quality plastics for tools and spectacle frames, photographic and tamper-evident films and finishing lacquers.
Lyocell
- Given their particularly high strength and moisture absorbent properties, lyocell fibres are suited for use in non-woven applications in the healthcare, industrial and disposable product markets, as well as in fashion textiles.
Viscose staple and filament fibres
- Viscose staple (Rayon) and filament fibres are used in the manufacture of fashion and decorating textiles, which have a soft, natural feel and excellent breathing properties.
- They are also well suited for use in non-woven applications.
Microcrystalline cellulose (MCC)
- The excellent cohesion properties of microcrystalline cellulose are exploited in the pharmaceutical industry where it is used as a binding agent in the manufacture of tablets.
- The colloidal properties of MCC and its ability to mimic fat droplets also make it an ideal rheological modifier (thickening agent) for the food industry, particularly in reduced fat products.
Cellophane
- With its excellent breathability and non-static properties, cellophane is used in packaging and adhesive tapes in the food industry.
- In specialised areas, cellophane is also used as alkaline battery separators, release agents and red lithographic masking tape.
Ethers (CMC, MC and HEC)
- Ethers are used in food applications, pharmaceuticals, detergents, drilling fluids, and cosmetics, as well as applications such as paper sizing.
- Cellulose sponge has excellent moisture absorbent characteristics and is used in both household and industrial applications.
Over the years, Sappi Chemical Cellulose has maintained its reputation as a world-leading pulp supplier by constantly investing in the best technology available to improve the quality of its products for customers worldwide.
Our milestones
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2010 |
- Sappi Saiccor renamed to Sappi Chemical Cellulose.
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2008 |
- Commissioning of the US$480 million AmaKhulu expansion project to increase capacity to 800,000 tons per annum.
- LignoTech expansion project to increase production by a further 40,000tpa at a cost of US$10.5 million.
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2004 |
- Modernisation project to de-bottleneck production at a cost of US$40 million.
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2003 |
- LignoTech lignosulphonate recovery plant upgraded to 155,000 tons per annum.
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1999 |
- Extension of existing effluent pipeline to 6.5km offshore completed and commissioned.
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1998 |
- LignoTech lignosulphonate recovery plant (a 50/50 joint venture between Borregaard of Norway and Sappi) commissioned to extract lignin from the mill's effluent, thus reducing discharge into the sea.
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1995 |
- Completion of the US$221 million Mkomazi Project, which enabled the mill to diversify its product range, upgrade quality and increase capacity to 600,000 tons per annum. In addition, the upgrade enabled the introduction of Elemental Chlorine Free (ECF) bleaching, significantly reducing the mill's environmental footprint.
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1992 |
- Mill produces 1,250 tons per day and achieves ISO 9002 certification, highlighting the mill's focus on quality.
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1988 |
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1981 |
- Through modifications and development Saiccor increases production capacity to 1,000 tons per day in order to meet the growing worldwide demand for pulp.
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1967 |
- Saiccor's effluent pipeline commissioned.
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1962 |
- Following extensions to the mill, production rises to 250 tons per day.
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1955 |
- The first plant and machinery installed in June and the first viscose pulp bales produced in December; the design capacity of the plant being 110 tons per day.
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1952 |
- Construction commences on the chemical cellulose manufacturing mill. Saiccor is the first mill to produce chemical cellulose from Eucalyptus - an important milestone that has revolutionised the industry.
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Our environment
Every employee at Sappi Chemical Cellulose is committed to responsible environmental management, which includes a policy aimed at the continual improvement of our environmental performance and compliance with the ISO 14001:2004 international environmental standard. The mill is also ISO 9001:2008 and OHSAS 18001:2007 certified.
All Chemical Cellulose 's employees are trained to understand, implement and maintain our Environmental Management System. The focus and content of the system is also communicated to interest groups, local authorities and communities through the media and community forums.
Main areas of our environmental performance are:
- The quality of the mill's effluent disposal improved due to the installation of a 155,000 tons per annum lignosulphonate recovery plant. This, together with the extension of the effluent pipeline to 6,5km offshore, was preceded by extensive public participation in an Environmental Impact Assessment.
- Water usage has steadily decreased by up to 900% since 1955 and is benchmarked against other chemical cellulose producers.
- Emissions of particulates and sulphur dioxide from the site have been reduced by 84% following the installation of various scrubbers and other improvements.
Our community
Sappi Chemical Cellulose has an extensive corporate social investment (CSI) programme, which concentrates on the following areas of need:
Education and training
We invest in a number of initiatives that are geared towards upgrading the skills of teachers, introducing computer literacy and computer based learning. Sappi Chemical Cellulose also established a PROTEC initiative, which gives learners from the surrounding schools the opportunity to learn and acquire knowledge and skills in Mathematics and Science.
Environmental awareness and education
We instituted a number of environmental awareness programmes, which are aimed at educating not only our employees, but the surrounding community as well, through the hosting of environmental awareness trips for children and adults.
Social welfare
Projects are in place, which is aimed at building, nurturing and supporting communities. In particular, programmes aimed at alleviating the HIV/Aids pandemic and related illnesses are regarded as a priority. By running workshops and seminars within communities and distributing educational material, we hope to raise the level of awareness and consequently build a healthier community.
In addition, Sappi Chemical Cellulose sponsors and supports various community initiatives such as libraries and learning centres.
Technology Centre
Sappi Chemical Cellulose operates in international markets, with a focus on continuous improvement, whilst utilising the benefits of the latest developments in technology. The Sappi Chemical Cellulose Technology Centre is at the heart of the company vision and strives to develop improved grades for existing markets and regularly introduces new grades for new applications.
Pilot cooking and bleaching equipment is used to investigate the effect of process and raw material changes on our final products. In addition, pilot plant facilities for viscose, cellulose acetate and cellulose ethers production allow a thorough assessment of the performance of Sappi Chemical Cellulose pulp in these applications.
A comprehensive understanding of our customers' processes and the impact of our pulp on their product quality obtained in this way provides us with the tools required to identify and 'tailor make' products that are best suited to each specific end-use and to each specific customer.
More fundamental research on the chemical and physical properties of cellulose, including reactivity and accessibility, which have a significant impact on product performance in our customers' processes, is also conducted.