The largest LNG-powered cogeneration unit in southern Poland – Schumacher Packaging Myszków

The Schumacher Packaging plant (now part of the Saica group) in Myszków needed to significantly increase energy efficiency and reduce dependence on rising electricity and heat costs, which are key in production processes such as paper drying. Initial plans assumed the installation of a 1 MW cogeneration unit, but detailed analysis revealed that the facility's actual energy needs were several times higher. The biggest challenge was adapting the infrastructure to supply a 4.4 MW engine – the existing LNG regasification station could not provide sufficient gas, and it was also necessary to integrate the new installation with the facility's extensive network of heat and energy sources.

Key challenge of the Myszków plant modernization:

• Scaling the gas installation – the initial 1 MW project was expanded to 4.4 MW, requiring the LNG regasification station to be increased by more than 100%.
• Integration of new and existing systems – connecting cogeneration with the gas boiler, coal CHP, and other installations required advanced design and network solutions.
• Flexibility in energy management – the plant needed the ability to smoothly switch and combine energy sources (steam, electricity, heat) depending on production needs.

Scaling the gas installation

With a 1 MW cogeneration unit, the existing LNG gas station was sufficient, but after increasing capacity to 4.4 MW, the cogeneration would consume almost twice as much gas as the station could supply without freezing. To solve this, we expanded the LNG regasification station, more than doubling its capacity, enabling supply to the engine and other processes in the facility.

Diversification of energy sources

Thanks to the expansion, the facility can now use not only cogeneration but also the CHP and gas boiler. This allows flexible energy production management. Depending on the demand for different media – steam, electricity, or heat – installations can be used interchangeably or combined.

System integration

Designing and integrating all new and existing installations, such as the gas boiler, coal CHP, and cogeneration unit engine, was key to achieving the facility's full energy efficiency. Designing all installations and connections and obtaining permits took about a year. At Schumacher Packaging, almost the entire thermal energy installation was designed and executed by the DB Energy engineering team.

We complemented the system with control and monitoring systems, allowing ongoing parameter oversight and optimization of installation operation.

The project at Schumacher Packaging demonstrates how a comprehensive approach to energy modernization – from audit, through design, to integration of multiple energy sources – achieves tangible technical and financial effects. Implementing LNG cogeneration on such a scale in southern Poland is an example of a bold investment that significantly increased the facility's energy independence.

The implementation shows that even with complex challenges – such as the need to expand the LNG regasification station, integrate with existing infrastructure, or change the project scale – proper planning and engineering experience enable effective execution.

Within about three years, the installation will fully pay off, and the facility will benefit from lower energy costs and greater supply stability, providing a strategic competitive advantage for Schumacher Packaging.

Schumacher Packaging (now Saica Group) is one of the largest producers of paper packaging in Europe. The company specializes in producing corrugated and solid board packaging, delivering its products to various industrial sectors worldwide.