Packaging solutions provider Cascades’ recycled linerboard production facility was developed in the existing Bear Island paper mill in Hanover County, Virginia, US.
The Bear Island paper manufacturing facility was acquired by Cascades from paper production company White Birch Paper for $34.2m in July 2018. The plant was temporarily operated by White Birch Paper as a newsprint mill under a 27-month lease period.
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In October 2020, Cascades announced its plans to halt the newsprint machine at the Bear Island mill and produce containerboard for the North American market.
The $380m project is part of the company’s strategy to invest in innovative packaging solutions and expand its geographical footprint across the US market. It also offers downstream converting capacity for the company and strengthens its containerboard operations.
The Bear Island mill’s newsprint paper machine was reconfigured to produce lightweight recycled and medium linerboard. Cascades produced the first roll of 100% recycled containerboard at the facility in May 2023.
The project created 700 jobs during the construction phase and 180 permanent jobs after completion.
Location details of Cascades’ recycled linerboard production facility
The Bear Island paper plant is located on a 1,620-acre site at 10026 Old Ridge Road in Hanover County, Virginia.
The Bear Island site was selected as an ideal location for Cascades’ recycled linerboard production facility due to the availability of raw materials and logistics within the region.
In addition, the plant’s existing newsprint paper machine, which was well-adapted for conversion into the containerboard machine under the initiative, was another reason for choosing the site.
Details of Cascades’ recycled linerboard production facility
The 601,000ft² facility is equipped with an 8,500mm-wide containerboard machine PM 1, which was converted to produce recycled linerboard. The machine features a headbox and sizer and required upgrades to the forming, press, and drying sections in addition to the reel. The headbox also features a quality control system and two scanners.
The facility has an annual capacity of 465,000 US tons (t) of 100% recycled linerboard and medium fluting paper.
The linerboards are available in various thicknesses by basis weights in accordance with the customers’ required surface smoothness and degree of rigidity.
Financing for Cascades’ recycled linerboard production facility
The Government of Virginia provided a $1.95m grant for Cascades’ recycled linerboard production facility via the Commonwealth’s Opportunity Fund.
The Virginia Jobs Investment Program also provided services and funding to support job creation and employee training activities at the site.
Cascades also received sales and use tax exemptions for its manufacturing equipment.
Contractors involved
Valmet, a supplier of technologies and equipment for the paper and pulp industry, was responsible for converting the existing newsprint paper machine to produce recycled linerboard. The scope of the contract also included automation services.
Enerquin, a building ventilation solutions provider, was contracted to supply building ventilation systems for the project in July 2021.
Kemira, a chemical solutions provider, was chosen as the main chemical supplier for the project in December 2021.
Marketing commentary on Cascades
Cascades was originally founded in 1964 and is focused on the recovery, manufacture, conversion, and marketing of corrugated packaging products, tissue products, and other speciality items, which are primarily made from recycled fibres.
The company is one of the largest collectors of recyclable materials in Canada and offers several varieties of food packaging products and material handling products.
Based in Quebec, Cascades employs more than 10,000 people and operates approximately 80 production units across North America and Europe.
