Biologicalisation of manufacturing on a factory scale - Taking a wider approach to envision a biologically transformed pulp-factory

The biologicalisation of manufacturing (BoM) is becoming a major driver for innovation, rendering conventional production processes more sustainable and efficient. So far, most biological transformation approaches focus on improving single technologies or materials in the production chain irrespective of the adjacent processes. However, the potential for BoM might even be greater if a broader approach is taken. Similar to how biological systems achieve efficiency by utilizing self-sufficient, highly interconnected processes, linking multiple individual BoM-technologies in a factory environment could lead to previously unattained improvements. This paper examines the potential of such a holistic transformation using the example of a manufacturing process from the pulp and paper industry. A production process for bleached pulp based on the chemical kraft process was chosen and screened for its inherent environmental challenges. Existing bio-based optimization approaches were then collected and assigned to the production steps followed by an evaluation of possible synergies and interactions concerning their simultaneous implementation on a factory scale. The survey revealed similarities and interlocking functions for a wide variety of BoM-technologies that might help to overcome some of the current hurdles faced in their individual implementation. Based on the findings a vision is presented about i) how a factory scale BoM holds the potential to improve sustainability of kraft pulp production in the short term and ii) how it could play a role in enabling more flexible and circular processes in the long term. The presented ideas should thereby serve as an impulse for a general investigation of wider biologicalisation approaches and provide a starting point for the creation of systematic methodical procedures to investigate and evaluate biological transformation processes on a factory scale.