Energy Efficiency Generates Annual Savings of $120,800 in a Paper Manufacturer in Santa Catarina, Brazil
Project under ANEEL/CELESC’s Energy Efficiency Program executed at IPEL and coordinated by Eletron Energia. The initiative automated production line electric motors, achieving a 42% reduction in energy costs for optimized equipment
The paper manufacturer IPEL has implemented, at its Indaial, Santa Catarina (Brazil) facility, a modernization project for the cellulose pulp preparation system, led by Eletron Energia S.A. The initiative replaced fixed motor starters with variable frequency drives (VFDs) equipped with dedicated process automation, allowing dynamic adjustment of motor speed according to process requirements.
The result was a 42% reduction in electricity consumption for the optimized equipment, equivalent to monthly savings of about $10,065, or approximately $120,800 per year.
According to IPEL’s general director, Luciano Barboza, high energy consumption has always been one of the main operational challenges. For this reason, the company has long developed energy efficiency projects focusing on environmental and operational benefits.
“This project developed by Eletron Energia brought a significant improvement to our processes, delivering tangible results for IPEL. More than that, it reinforces our commitment to sustainability and the long-term continuity of our business,” Barboza stated.
Integrated Engineering and Automation
Before modernization, the motors in IPEL’s pulp preparation sector operated 24 hours a day, even without active load, leading to excessive energy consumption and premature wear.
“It was like keeping a car revving in neutral all the time,” explains Alisson D’Agostin, Automation Specialist at Eletron Energia.
At that time, the system used soft starters, devices that smooth motor startup but do not allow speed control during operation. With the introduction of variable frequency drives, the motors can now operate at a variable speed, adapting to actual process demand.
The update also included the pulp pumping system, which was previously regulated manually using valves.
“The motor ran at full speed, and pressure was controlled by partially closing the valves, a less efficient approach,” says D’Agostin.
The automation enabled precise pressure control through frequency variation, enhancing efficiency and reducing mechanical wear.
Eletron Energia fully developed the motor control centers and the automated logic. Now, the operator selects parameters according to the type of paper being produced, and the system automatically adjusts time, volume, and rotation for optimal efficiency and process standardization.
“In summary, this project implemented variable frequency drives and a dedicated automation system, ensuring greater process reliability along with significant gains in energy efficiency and operational performance,” adds Victor Moraes, Engineer at Eletron Energia.
Financing Model and Investment Payback
The project, registered under code PE-05697-0115/2024 and titled “Indústria + Eficiente – IPEL Papel”, was fully financed by the Celesc Energy Efficiency Program (PEE), under regulation by the Brazilian Electricity Regulatory Agency (ANEEL).
Eletron Energia conducted all feasibility studies, detailed design, and commissioning, as well as secured the funding.
“Celesc’s Energy Efficiency Program can be fully subsidized by the utilities, and the investment payback comes from the savings generated after implementation. It’s a model that enables improvements without direct costs to the company, making energy efficiency even more accessible,” notes D’Agostin.
According to him, the expected payback period is 18 months. Initial performance measurements already confirm the effectiveness of the improvements, which continue to be technically monitored.
Efficiency Combining Sustainability and a Forward-Looking Vision
IPEL’s general director emphasizes that the pursuit of efficiency is strategic in a highly competitive sector.
“We operate in the Tissue segment, producing sanitary paper products, which is extremely competitive,” he says. Thus, initiatives that help reduce operating costs —especially energy — are essential.
“This project not only strengthens our sustainable DNA but also enhances our competitiveness. These two factors go hand in hand and were decisive for the project’s success, which is already operating and delivering highly positive results.”
More than a business strategy, actions like IPEL’s align with Brazil’s broader energy transition agenda. As the country advances in public policies for decarbonization and gains global recognition for its mostly renewable power matrix, industrial energy efficiency initiatives become key to meeting emission reduction targets and promoting rational resource use.
For Engineer Victor Moraes, from Eletron Energia, the IPEL case exemplifies how energy efficiency can take a leading role in this transformation.
“Projects like IPEL’s must continue to gain traction. The company’s pioneering and highly strategic approach makes it an excellent example of how to combine sustainability and competitiveness intelligently,” concludes Moraes.
About IPEL
IPEL is one of Brazil’s largest manufacturers of sanitary and disposable paper products. Founded in 1984, the company is headquartered in Indaial, Santa Catarina (Brazil) and produces over five thousand tons per month. It operates in both institutional and consumer markets, with a focus on innovation, social and environmental responsibility, and sustainability.
