Leuna Biorefinery: How Bilfinger Powers UPM’s Vision for Sustainable Chemical Innovation
At UPM’s groundbreaking biorefinery in Leuna, Germany, the transition from construction to commissioning is more than just a procedural step—it marks a pivotal moment in the journey to redefine the future of the chemical industry. With the technical completion phase now wrapped up, the baton has been passed to the commissioning and ramp-up team, propelling the project toward commercial operations slated for the second half of 2025.
This site isn’t just another industrial facility—it’s a global first-of-its-kind, where wood-based raw materials will be transformed into renewable, bio-based chemicals. The ambition? To revolutionize an industry long reliant on fossil fuels and bring us closer to a circular, sustainable economy. And at the heart of this transformation is a critical collaboration with industrial services provider Bilfinger, whose expertise and innovation have played a foundational role in keeping the project on track.
From Blueprint to Biorefinery: A Complex Technological Landscape
The Leuna biorefinery is a technological powerhouse, integrating over 30 novel technologies—including mechanical wood processing, enzymatic treatment, and chemical synthesis—many of which have never before been combined in a single industrial operation. This creates a unique set of operational demands, especially when it comes to maintenance.
Unlike traditional chemical or petrochemical facilities, Leuna’s configuration is completely new, requiring creative problem-solving and a tailored approach to ensure every component works harmoniously. That’s where Bilfinger’s diverse sector expertise—from pharmaceuticals to energy and oil & gas—has been invaluable.
Innovative Maintenance: Custom Solutions for a First-of-Its-Kind Plant
To support UPM in this highly complex environment, Bilfinger implemented its Bilfinger Maintenance Solution (BMS), a structured and data-driven methodology that ensures transparency, efficiency, and proactive management of plant maintenance.
Weekly meetings and on-site inspections between UPM and Bilfinger teams create a continuous feedback loop—essential for refining systems in such a unique production setting. This hands-on, collaborative approach ensures that maintenance strategies evolve alongside the plant’s ramp-up phase.
One early example of this adaptability was during commissioning, when malfunctioning valves were identified. Rather than discard them, Bilfinger refurbished and reinstalled the components—an action that both reduced waste and upheld the sustainability standards that UPM holds central to its operations.
Safety and Trust: A Partnership Built on Reliability
Safety is non-negotiable at Leuna, and both UPM and Bilfinger share a common commitment to creating a secure working environment. Feedback from UPM’s own maintenance staff during commissioning revealed a strong sense of confidence when working alongside Bilfinger—some even stating they felt safer with Bilfinger than with the original equipment manufacturers.
This speaks volumes about Bilfinger’s attention to detail, rigorous safety protocols, and quality assurance processes. Defective electrical panels and other potential issues were quickly flagged by Bilfinger’s teams—often before they became operational problems—demonstrating a proactive and preventive approach to safety.
Sustainability Beyond Words: Real Actions, Real Results
Both UPM and Bilfinger have been recognized for their environmental and social governance (ESG) commitments. UPM holds a Platinum EcoVadis rating, while Bilfinger boasts a Gold rating, reflecting their shared values in ethical business practices and environmental stewardship.
What sets this partnership apart, however, is how those values translate into real-world actions. Whether it’s refurbishing hardware during commissioning or aligning with the goals of UPM’s “beyond fossils” strategy, Bilfinger has proven to be more than just a contractor—it’s a partner in long-term sustainability.
Commercial Production and Market Demand
As the refinery approaches full-scale operations in late 2025, early signs are highly promising. The market pipeline for the Leuna biorefinery’s products and by-products already exceeds the site’s annual capacity, signaling strong global demand for sustainable alternatives in the chemical industry.
The Leuna facility will produce advanced renewable biochemicals from wood—helping replace fossil-based inputs in everything from plastics to textiles, adhesives, and cosmetics. This will make a significant contribution to lowering the carbon footprint of multiple industries.
About Bilfinger: Industrial Services for a Sustainable Future
Bilfinger is a global industrial services provider supporting the process industry in increasing both efficiency and sustainability. Its comprehensive offerings span consulting, engineering, manufacturing, maintenance, and digital services, allowing the company to deliver value across the full industrial lifecycle.
With a presence in Europe, North America, and the Middle East, Bilfinger serves key sectors such as energy, chemicals & petrochemicals, pharmaceuticals, and oil & gas. At Leuna, this expertise has translated into smarter maintenance, safer operations, and a shared commitment to sustainable industrial transformation.
Building a New Standard for Green Chemistry
The partnership between UPM and Bilfinger at the Leuna biorefinery is a living example of what’s possible when innovation, collaboration, and sustainability converge. As the facility enters its commissioning and ramp-up phase, the work being done isn’t just powering a new plant—it’s powering a new way of thinking for the global chemical industry. And with partners like Bilfinger, UPM is demonstrating that the future of green chemistry is not just a concept—it’s already under construction.
