Smurfit WestRock, a paper and packaging company, developed a new corrugated box manufacturing facility in Pleasant Prairie, Wisconsin, US, to meet increasing demand from customers in the Great Lakes region.
Announced in January 2024, the manufacturing facility project involved an investment of $140m.
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The ground-breaking ceremony for the project was held in June 2024. The facility was completed in March 2025 and created 200 jobs.
Smurfit WestRock transitioned its North Chicago operations to the new facility, which enhances the company’s production capabilities and improves its cost profile in this key geographical area.
Since opening in 2025, the corrugated box plant has been helping meet growing demand across the Great Lakes region, serving dairy and processed food, consumer goods and industrial markets.
Location of Smurfit WestRock’s new corrugated box plant
The corrugated box facility is located in the LogistiCenter®, a three-building logistics and distribution hub with a total building space of 2.38 million square feet (221,551m²).
Smurfit WestRock entered a build-to-suit lease agreement with Dermody Properties, a national real estate investment, development and management company, to build the facility at LogistiCenter.
The strategically located logistics park is the only rail-served, build-to-suit logistics park in Wisconsin and is part of a series of industrial developments by Dermody Properties. It offers immediate access to a major interstate highway, I-94, via a four-way interchange and boasts dual rail service, courtesy of Union Pacific and the Canadian Pacific Railway.
Pleasant Prairie has become a growth hub due to its business-friendly environment, available labour force and high quality of life, making it an attractive location for companies looking to access the Midwest market.
Smurfit WestRock corrugated box facility details
Smurfit WestRock’s corrugated box plant occupies more than 593,565ft² within LogistiCenter. It is developed into a regional corrugated operations hub in the Great Lakes region with advanced automation and enhanced capabilities to improve product quality and customer satisfaction.
The facility’s design focuses on reducing production waste and expenses, thus improving Smurfit WestRock’s overall manufacturing cost profile. It also prioritises sustainability by utilising less energy and incorporating innovative technologies.
With an emphasis on digital capabilities, the facility provides real-time data to enable better decision-making and reduce unplanned downtime.
The facility also includes 27,000ft² of office space, a quality lab, maintenance shop, and direct Union Pacific rail access for raw material delivery through five rail spur lines. It is equipped with three 4,000A, 480/277V main switchboard services and features an early suppression fast response (ESFR) fire sprinkler system, fire alarm and notification system, and LED lighting solutions.
Additionally, it is equipped with four rail storage sidings and indoor rail access to support delivery of 120in-wide, three-tonne paper rolls.
Extensive heating, ventilation, and air-conditioning (HVAC) systems have been installed for air exchange and environmental control requirements.
Smurfit WestRock Pleasant Prairie facility product portfolio
Smurfit WestRock’s corrugated box plant in Pleasant Prairie specialises in corrugated boxes, sheets and trays, e-commerce packaging, retail and high-graphics packaging, industrial packaging, protective packaging, retail displays, and speciality packaging.
The facility manufactures both double-wall and triple-wall corrugated solutions, jumbo and wide‑format packaging, supporting high‑volume runs in B, C, D and E flute profiles. It also produces food-safe packaging certified by the Safe Quality Food (SQF) Institute and utilises four-colour direct printing.
Additionally, the facility offers in-house design support and can arrange performance testing before full production. For high-impact graphics, it provides both direct print and inside preprint, ideal for consistent patterns and precise cut-to-mark designs.
The Pleasant Prairie facility uses renewable, recyclable and recycled content to deliver more sustainable packaging. The site holds Chain of Custody certifications from the Forest Stewardship Council (FSC®), Programme for the Endorsement of Forest Certification (PEFC™), and Sustainable Forestry Initiative (SFI®).
Contractors involved
Partners In Design Architects, a design and architecture company, designed the corrugated box facility.
Riley Construction, a construction management, general contracting, and design-build services company, served as the general contractor for the project. Riley was also involved in the construction of five rail spur lines that connect to the Union Pacific mainline.
Lee Mechanical, a plumbing, HVAC, electrical, and mechanical construction services provider, delivered comprehensive electrical services, including interior and exterior lighting solutions.
Marketing commentary on Smurfit WestRock
Smurfit WestRock is dedicated to transforming the lifecycle of paper, from production to reuse, and is actively working towards a future centred around fibre-based materials. Its offerings also encompass pulp products and retail displays.
The company caters to a diverse range of industries, from beauty and personal care to healthcare and tobacco. It places a strong emphasis on sustainability and community well-being, with a focus on fostering partnerships and collaboration to enhance its operations.
Smurfit WestRock’s operations span across 40 countries with approximately 96,000 employees. Apart from the Wisconsin facility, the company also operates a corrugated box facility in Washington, US.
