GEA provides water treatment components for Lignatherm insulation plant

GEA is supporting Lignatherm AG in Küssnacht, Switzerland, with the supply of key components for a customized, three-stage water treatment solution at its new wood fiber insulation board factory in Küssnacht. Lignatherm's goal is to produce wood fiber insulation boards with the lowest possible environmental impact. The new plant is scheduled for completion in fall 2025 and will process around 50,000 tons of wood chips per year into high-performance, resource-saving insulation boards.

A breakthrough in water-saving production – a three-stage process
At the heart of the plant is GEA's customized water treatment process, which is applied at three different critical points in the production process to ensure that more than 95 percent of the wastewater can be reused as steam – which also reduces the demand for fresh water by over 95 percent. The three-stage process is as follows. The first stage involves mechanical separation using GEA decanter centrifuges. Here, suspended solids are effectively removed from the wastewater stream. The second stage is thermal separation using a falling film evaporator. Here, the dissolved solids are concentrated for later disposal, while clear condensate is produced for feeding into the third stage. This stage is particularly resource-efficient thanks to the mechanical vapor compression (MVR) system, which operates the evaporator without fossil fuels at maximum energy efficiency. This system achieves a coefficient of performance (COP) of more than 25. This is at least five times higher than other heating options such as heat pumps or gas boilers. The third stage consists of a GEA steam reformer. This stage ensures complete recirculation of the water recycling system by collecting the wastewater in a loop where it is converted into process steam, so that no steam needs to be generated otherwise.

By drastically reducing fresh water consumption and minimizing wastewater discharge, the solution sets a new benchmark for sustainability in the wood processing industry. "Our innovative three-stage process not only meets Lignatherm's ambitious environmental goals, it exceeds them. It shows what is possible when technology and sustainability go hand in hand," said Roland Moser, Evaporation Sales & Process Manager at GEA.




A model for collaboration with industry
The success of this project is the result of a close partnership between GEA and Lignatherm, underpinned by open communication and shared values. “From day one, GEA's expert advice and cooperative approach helped us develop a solution tailored to our demanding standards,” said Tobias Osterwalder, Head of Processing and Managing Director at Lignatherm. “Together, we are proving that sustainable production and responsible environmental management can drive industrial innovation.”

Setting new standards for water protection
GEA's three-stage water treatment system benefits from the company's centuries of experience in thermal separation and chemical processing. The solution is specifically tailored to the unique challenges of wood fiber production and ensures maximum water savings and energy efficiency – even with seasonal fluctuations in raw material properties.

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