Inside commissioning and ramp-up phase at UPM's Leuna biorefinery

Commissioning is a critical phase that tests and validates every system and component to ensure they function safely and efficiently before full production. We always need strong and reliable partners that share similar values and help us to comply with our sustainability goals. Behind our cutting-edge biorefinery are strong partnerships like the one with Bilfinger, an international industrial services provider. Their six-year collaboration is proving essential in commissioning, ramping up, and sustaining our innovative Leuna plant.

Proof of concept: How our maintenance partner Bilfinger powers efficiency, innovation, and sustainability

It's crunch time in Leuna! Handing over the site post-technical completion to the commissioning team marks a major milestone.

With our pioneering biochemicals biorefinery in Leuna, we aim to transform the chemical industry towards a circular economy. Once fully operational, we convert wood into advanced biochemicals at scale. This milestone reinforces UPM's role as a frontrunner in sustainable innovation. What we're building in Leuna is far more than a biorefinery. It's a powerful signal that more sustainable chemistry is not only possible, it's already happening, and we're leading the way.

Collaborative innovation driving plant efficiency

As the refinery integrates over 30 new technologies across mechanical wood processing, enzymatic treatment, and chemical synthesis – many never combined before – it places special demands on maintenance.

Expertise across sectors meets unique demands

While Bilfinger's experience spans chemicals & petrochemicals, energy, oil & gas, and pharma & biopharma, the Leuna biorefinery is unlike regular customers. The plant's complexity and novelty require specialized approaches, not only to find the right technology for the final products but also for their upkeep.

Bilfinger has experience in handling sensitive data through its “Bilfinger Maintenance Solution (BMS). Together with UPM, they established a continuous exchange process involving weekly meetings and onsite inspections. This ongoing cooperation is vital for creating and improving tailored maintenance methods.

Commitment to sustainability in action

Sustainability lies at the heart of this partnership. Bilfinger's EcoVadis Gold rating and UPM's Platinum score reflect aligned commitments to ethical, environmental, and social responsibility.

A practical example is Bilfinger's prompt checking and repair of numerous malfunctioning valves during the commissioning process. Instead of discarding these critical components, Bilfinger restored and reinstalled them, reducing waste and supporting UPM's sustainability targets.

Safety first: Ensuring reliable and secure operations

Safety standards at Leuna are exceptionally high, reflecting the values of both UPM and Bilfinger. During the commissioning of the plant, UPM maintenance staff reported feeling safer working with Bilfinger than with the original equipment manufacturer, a testament to Bilfinger's rigorous oversight and quality control.

Bilfinger continuously monitors compliance with UPM's requirements onsite and remotely, promptly communicating design issues such as defective electrical panels, thereby maintaining transparency and trust.

Commissioning and start-up underway towards full operation

Commercial production at the Leuna site is expected to begin in the second half of 2025. Commercial interest in the products and side streams is confirmed with an opportunity pipeline multiple times the annual capacity of the refinery.

Bilfinger's proven expertise and innovative maintenance solutions are key indicators that our Leuna biorefinery is on track to succeed. Through close collaboration, tailored technology, and a shared commitment to sustainability and safety, this partnership exemplifies how cutting-edge industrial transformation can become a reality.

About Bilfinger

Bilfinger is an international industrial services provider that increases the efficiency and sustainability of customers in the process industry.

With a comprehensive service portfolio that includes consulting, engineering, manufacturing, assembly, maintenance and digital applications, Bilfinger covers the entire value chain.

Active in Europe, North America and the Middle East, Bilfinger serves customers in the chemicals & petrochemicals, energy, oil & gas, and pharma & biopharma sectors.