The new facility recycles recovered papers. Image courtesy of Pratt Industries, Inc.
Pratt Industries announced the construction of a recycled paper mill in September 2013. Image courtesy of Pratt Industries, Inc.
The fourth facility enables Pratt to achieve an overall containerboard production capacity to 1.5 million tonnes. Image courtesy of Pratt Industries, Inc.

Corrugated packaging company Pratt Industries has unveiled a new 100% recycled paper mill in Valparaiso, Indiana, US. Construction of the $260m mill site began with the ground-breaking ceremony held in March 2014 and the mill was opened in October 2015. The company announced its decision to construct the fourth production line in September 2013.

The 100% recycled paper mill produces papers for sustainable lightweight packaging. It is the most technologically advanced and eco-friendly mill worldwide, bringing the company’s overall containerboard production capacity to 1.5 million tonnes.

Pratt’s new plant has an initial production capacity of 370,000t per annum (tpa).

Plant details

The new mill is located near Pratt’s existing 500,000ft² box-making plant, which is the biggest box-making plant in the world.

“The 100% recycled paper mill produces papers for sustainable lightweight packaging.”

Built across 250,000ft² within a 50-acre site, the new plant implements advanced recycling technologies. It showcases 21st century recycling technology, and features a wastewater pre-treatment facility and road improvement.

Mill equipment

The recycled paper mill principally uses recyclable products for the production of paper. It is installed with advanced solutions to increase the efficiency of materials and optimum use of energy. It also considerably reduces water consumption through process stabilisation and optimisation.

In June 2014, Pratt contracted Metso to supply automation packages for the new plant. Metso supplied a large automation package for the new PM 16 packaging paper production line installed at the mill.

The scope of delivery also included Metso DNA automation system, Metso IQ quality control system with Metso IQ dilution profiler for a dilution headbox, and Metso IQ moisturiser system, whose patented air sealing technology helps in removing moisture.

Sustainability features

Pratt’s new facility added 120 new jobs to the existing 280 workers at the company’s box manufacturing facility nearby. The company hired paper machine operators, equipment operators, electrical and instrumentation technicians, shipping representatives, waste yard personnel, shift supervisors and maintenance associates.

LINPAC Packaging has designed a unique packaging solution known as LINslice, for use in vacuum bagging applications.

The freight costs were negligible due to its close proximity to the existing box factory.

Green recycling technology saves approximately 20,000 trees and divert up to 3,500 cubic yards of waste from landfills every day.

Marketing commentary

Headquartered in Georgia, Pratt Industries is the fifth biggest corrugated packaging company in the US and the world’s biggest privately held 100% recycled paper and packaging company. The company recovers almost 3,000t of recovered paper a day. It has approximately 130 manufacturing facilities in the US.

It operates an extensive recycling company, which supplies three of the 100% recycled paper mills in New York, Georgia and Louisiana.

Pratt offers a wide variety of creative packaging solutions through sheet plants, full-line corrugated box factories and display facilities spread throughout the US and Mexico.