What are a manufacturer’s environmental impacts? Besides the production, transport and packaging have a relatively high environmental impact. Regarding packaging, cardboards and folding boxes are often the material of choice. But even with recycled cardboard, a certain amount of virgin wood fiber is still needed to produce it – which means that trees have to be felled. Is there a way to make these wood fibers obsolete?
Creapaper GmbH, The Grassfiber Company, situated in Germany, is creating new methods and uses grass fibers as a raw material to produce paper and cardboards .
Let’s take a closer look at what grass paper is and how it compares to other materials from an environmental perspective.
How paper and cardboards are made today…Today, the majority of our paper and cardboards are produced from either fresh fibers or recycled paper. The production process for paper and cardboard made from virgin wood fibers is very energy- and water-intensive. Cellulose fibers, which are the basis for paper products, must be separated from lignin, hemicellulose, and resins. For this purpose, the debarked wood in the form of wood chips is boiled in the sulphate process with sodium hydroxide and sodium sulphide at temperatures around 170 °C/175 °C, under high pressure for two to three hours. The paper then has to be bleached using chlorine dioxide or oxygen, hydrogen peroxide or ozone.  Not forgetting the transport of the raw material– often the source of high energy consumption and environmental pollution. The wood for paper production comes from all over the world and only a small part comes from Germany. This results in very long transport distances of several thousand kilometres. [3, 6]
The most common alternative to paper made from fresh fibers is the use of recycled paper - after all, a cellulose fiber can theoretically be reused up to six times.
The additional positive aspect is that up to 60% less energy and up to 70% less water is used to produce recycled paper . In 2018, waste paper was used for 76% of all paper produced in Germany. In figures, this is an impressive 17.2 million tons of recycled paper .
But even when using waste paper fibers to produce recycled paper, a certain amount of fresh fibers is still required, because with each recycling process the wood fibers are shortened and these shortened fibers must be replaced by longer, fresh fibers. Deforestation continues, even if at a reduced rate.
Isn’t there a way to replace these wood-based fibers and make the paper production more eco-friendly? This was the question that Uwe d'Agnone, founder of Creapaper, asked himself in 2014.
From wood to grass - a green idea is born: Grass paper
Many plants contain the basic material cellulose – just think of the Egyptians who wrote on papyrus. Newer paper developments experiment with hemp or bamboo. The idea was to replace fresh fibers from wood with grass fibers. Both materials contain pulp, the basic ingredient for paper. But grass has 75% less lignin and resin as wood, so it should be much easier to liberate the pulp. And is grass not growing everywhere?
The production process of grass paper is easy in comparison to wood-based paper production. Starting material is hay, dried grass which has been grown on regional agricultural compensation areas. The hay is being transported to the paper mill. There, it is cleaned, mechanically shredded, with the fibers being cut to a suitable length, and pressed to grass pellets. These pellets are then utilized directly in the paper production process without using any chemicals at all and resulting in the so-called “grass paper”. This final product is not 100% grass-based.