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PAC: Raw Material, Package Machinery & Ancillary - Silver

New Forest Paper Mills LLC

Overview

Located in Scarborough, Ontario, the New Forest Paper Mills facility is a joint venture between Atlantic Packaging and Mitchel-Lincoln and was brought about as a result of the increased demand for 100% recycled containerboard in the U.S. and Canadian markets. 100% recycled old corrugated containers is the source of material that is re-pulped, cleaned and remade into prime paper product to make corrugated containers. Their 100% recycled paper and corresponding cartons are converted from local sources and the actual recycling operation can be done in less than thirty minutes. The transportation component is very cost effective and has low greenhouse gas impact since everything from raw material source to the customer base is all located in close proximity to the facility.

Motivation for Change

New Forest Paper Mills is a joint venture between Atlantic Packaging Products Ltd and Mitchel-Lincoln. The facility was brought about as a result of the increased demand for 100% recycled containerboard in the U.S. and Canadian markets. Since Atlantic Packaging had sold out its original 100% recycled mill located at 111 Progress Ave, it only made sense to stay with the successful formula of producing recycled paper for corrugated packaging.

Performance

Since this is a new facility with a new paper machine using the latest technology, the facility is able to utilize and capture more fibre than older paper making families. The fibres are classified and separated with short and long fibres being treated differently to minimize damage. The fibres are cleaned and stored separately and then recombined in a recipe to maximize strength or printing properties as required for the grade or customer required characteristic. There is really no trade off for this facility as it produces the finest recycled paper that meets or exceeds all industry standards and while improving the carton making abilities of converting customers.

Sourcing

100% recycled Old Corrugated Containers (OCC) is the source of material that is repulped, cleaned and remade into prime paper product to make corrugated containers. Our 100% recycled paper and corresponding cartons are made to meet or exceed the industry standards while using the same amount or even less fibre in doing so. 100% recycled OCC is collected locally (some from back haul from paper deliveries), cleaned and reformed into a pristine paper product. The actual paper contains 90% Post Consumer OCC and some 10% Post Industrial scrap from our own converting operations.

Clean Production

We have a plume reduction system to capture evaporated water, normally sent into the air, for reuse in our process. Water from the papermaking and raw material cleaning process is cleaned continually and reused. We also take the wastewater stream from the mill and utilize the inherent Biological Oxygen Demand (BOD) potential of the dissolved solids in the water to maximize its use as an alternate or renewable energy source. Since glues used to make a corrugated carton are starch based. This is an excellent source, found in the raw material for the mill, for anaerobic organisms to feed and grow on. We utilize this natural biological activity to eat the BOD pollutants in the wastewater and generate Methane Gas. This created gas is then pumped to our boilers and is burned to offset the use of natural gas, normally used to heat the boilers for the paper drying process.

Effective Recovery

The corrugated container (OCC) is 100% recyclable and is a desired and valued commodity. It is collected and sold to a variety of users. The paper and glues used are all biodegradable. Technically there is no end of life to 100% recycled paper products. As long as the paper can be collected we can recycle it. The collection of old corrugated containers for recycling is well established at almost all businesses as well as curbside collection systems. We collect directly as well as purchase from an established series of collection agencies including municipal collection facilities. Atlantic Packaging Products part ownership of 3 Municipal Recycling Facilities (MRFs), including the latest one in Durham region allows us to collect not only our fibre requirements for New Forest and our other mills, but also contribute to the diversion of many more materials destined for landsite. Many of these materials do have market value and move from grave to cradle once collected and sorted. Technical studies claim a single paper fibre can be recycled 7 times before being so damaged as to be rejected. While we have no scientific proof we believe that fibre can and are recycled many more times. Our processes are specifically designed to minimize further damage to fibres and to maximize strength. Being a paper product the end result of use is either continued recycling or at worst under the correct conditions, is a biodegradable product.

Community Benefit

Since New Forest is located in an urban setting within yards of residential housing, retail malls and outlets, and other industrial sites, the facility is very “community friendly” and does little to disturb those area community stakeholders. This is something almost unheard of in terms of industry and communities interacting with one another. The city of Toronto has a major need to divert waste from landfill and our product is as a major destination for Toronto’s OCC collection stream. This is the first new containerboard mill built in Canada in 25 years, started up when all many other paper companies are in fact shutting mills down. This mill created 100 new high paying manufacturing jobs at a time that manufacturing jobs in Ontario are disappearing at an alarming rate. This facility also contributes to the local community by generating taxes into the city’s coffers. As a major recycler we offer educational tours for customers, environmental groups, government agencies, colleges and high-school classes, technical organizations etc. All statistics and claims are backed up by traceable standards and public domain information.

Material Health

Being 100% recycled paper the main processing consideration is the removal of all contaminants. The paper is metal free and passes all FDA and Canadian food quality certification. Any and all chemicals used in the paper making process are specifically selected for their non-toxic and benign environmental aspects.

Resource & Energy Optimization

Being an urban mill (in downtown Scarborough, Toronto) waste paper comes from local sources versus far-flung areas, is collected and converted back into pristine paper ready for packaging use. The actual recycling operation can be done in less than 30 minutes. The finished paper is delivered by truck to our own local converting plants, located in close proximity of the mill, to be made into new containers (corrugated packaging) and then delivered to local manufactures to package their finished products. Since everything from raw material source to the customer base is located very close to the facility, the transportation component is very cost effective and has low greenhouse gas impact on the entire supply chain.The primary resource used is OCC or waste paper. This facility diverts over 11,000 trucks from landfill each year. The recycling of fibre saves over 6 million trees per year from being harvested for papermaking. These trees represent over 3 million tonnes of carbon green house gas sequestered from the environment each year since they are left standing to do what they do best, remove carbon dioxide from the atmosphere. The average energy consumed to make virgin paper is 25 gigajoule per tonne (source NRCan) whereas for us to recycle and make the same quality paper takes 7 gigajoules per tonne. This represents less than 1/3 the energy of virgin paper mills. Our Green House Gas footprint is being tracked and continues to trend down. Our near term goal is to conduct audits by outside agencies in order to obtain carbon credits. Being an urban mill with all the sources of fibre and customer base within close transport area the GHG emissions for transportation are some of the lowest in the paper making industry.

Categories: Paper & Board PAC Award Winner Consumer Goods

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