Eucalyptus fluff: higher compression and proven lower costs

Eucafluff®, the world’s first eucalyptus-based fluff pulp, launched in 2016, is a relatively new product. Even with a short time on the market, its application has shown a consistent growth outlook among manufacturers across various hygiene product categories, driven by the competitive and environmental advantages it offers. One of these advantages was tested and proven by us at Optima, as it is directly related to one of our core businesses: the manufacturing of technological solutions, such as packaging machines for the hygiene industry. This advantage is the significant reduction in polyethylene (PE) consumption enabled by Eucafluff®’s higher compression capability.

How does Optima fit into this story?

Suzano’s application engineering team had already observed, through tests conducted with multiple customers in Brazil and abroad, that applying Eucafluff® in disposable diapers and similar products made it possible to produce thinner cores, creating a certain “slack” in the final packaging. It was also verified that higher compression could be applied to these cores without causing deformation or compromising product performance. However, until then, there was no clear quantification of these gains. Suzano therefore proposed a partnership with us to test the compression capability of diapers produced with Eucafluff® and measure the real benefits for disposable hygiene manufacturers.

Through tests carried out at Optima’s laboratory in Vinhedo (SP), we reached two main results when comparing two packs of pants-type diapers with 14 units each — one produced with pine fluff and the other with Eucafluff®:

Reduction of 18% (m²) in packaging material consumption.
Reduction of 13% (m³) in packaging volume, generating direct impacts on:
transportation costs
storage costs
reduction of environmental impact across the logistics chain

The gains can go beyond cost savings for the industry, delivering structural sustainability benefits through reduced plastic usage and improved logistics performance.

How were these tests conducted?

Relatively simple adjustments were made at two points in the test unit that simulates the processes of an Optima automatic packaging machine:

1. Compression system
   We tested the compression applied to diapers with Eucafluff® and identified that only 10% of the machine’s capacity was being used. Due to the characteristics of short fibers, it was possible to apply significantly higher compression without damaging the product.
2. Bag opening module
   As compression resulted in narrower stacks, it was necessary to develop new, smaller packages to properly accommodate the products.

In 2022, Optima celebrated 100 years of excellence in the development and implementation of new packaging technologies, supplying everything from individual machines to complete systems for the Pharma, Consumer, Nonwovens, and Life Science industries. In several areas, our technologies are global leaders, especially in the packaging process of disposable hygiene products.

For us at Optima, this partnership with Suzano has been delivering direct benefits not only to our shared customers, but also to the planet. The world needs solutions developed collectively, sustainably, and aligned with the pursuit of a more efficient and responsible industry.