Paper360 - November/December 2017 - 31

it was easy to underestimate the magnitude
of the task."
The mill produces two grades of linerboard: HP, or high performance; and XP, or
extra performance. The mill's basis weight
ranges are 18 to 35 lb.
The HP liner is more a commodity grade; the
XP is what Greenpac focuses on and it accounts
for a significant percentage of production. "We
produce to a guaranteed strength, not a basis
weight," Hewitt explains. "We add surface
starch with a metering size press to achieve
greater strength at a lower weight."
He likened it to a starched collar on a shirt.
"We add the starch to give the sheet stiffness
and stacking strength, but at a lower weight."
Customers include integrated plants and
boxmakers that convert liner and corrugating

medium to make boxes. As well as the region
around the mill, markets extend west and south
to Pennsylvania, Michigan, Ohio, Indiana,
Illinois, and even Texas. Most production, 75
percent, is shipped by truck, but the mill will ship
by rail to customers further afield, such as Texas.
Hewitt adds that the goal is to optimize
the combination between the liner and the
medium, based on the predictive properties of
XP. Customers can run faster on their corrugators at lower temperatures while increasing
output. "There has been a great reaction from
the market," Hewitt says. "It's very similar to
what they are already doing in Europe."
AN EXPENSIVE LESSON
Greenpac uses about 600,000 tpy of secondary fiber, mostly old corrugated containers

Greenpac uses about 600,000 tpy of secondary fiber, mostly OCC with some mixed waste paper.

Roll handling (Valmet) is also automated. The warehouse is totally automated with Kone cranes and
Raumaster grippers.

(OCC, 90+ percent) with some mixed waste
paper. Cascades Recovery provides all the fiber
needs for the mill.
Because Greenpac does not want to compete
with its sister mill for fiber, it does a lot of back
hauls from its own customers in New England
and Canada. As it also has a rail connection,
some fiber is sourced from Pennsylvania and
the US Midwest. The mill keeps about two
days' supply on site, with another five days'
inventory stored off site.
The two mills share a bale yard and suffered
a major blow in September 2014 when a large
fire destroyed about 10,000 tons of OCC. "It
was potentially catastrophic," Hewitt says.
The mills learned their lesson, though: they
adopted strict fire prevention procedures,
installed multiple water towers, and purchased
a fire truck.
Once in the mill, the fiber is fed into a
pulper. A ragger removes the wire from the
bales while a grapple takes other "junk" away.
The relatively clean fiber is fed to a dump chest
and then is processed through high-density
cleaners to coarse screens and then into a
fractionator. Long fiber is further cleaned
through fine screening, with accepts sent to
the disc filter for thickening and then into
storage. Short fiber from the fractionators goes
to thickening and then storage. Storage time
is about four hours.
Hewitt says that the mill has developed a
"recipe" between short and long fiber that
optimizes strength.
Voith supplied the OCC processing equipment including screens, cleaners, and fractionators. Voith Meri supplied the conveyor,
pulper, and detrashing and reject handling
equipment. The disc filter and refiners came
from GL&V.
Greenpac handles about 220 tons/day of
rejects from the pulping system. Plastics go
to Covanta to be burned to generate steam the
mill uses. Waste fiber is used for animal bedding, while metals are recycled. The mill ends
up sending a small percentage of its rejects to
landfills, but Hewitt hopes to eliminate this
totally by the end of 2018.
'RUNS LIKE A TOP'
The paper machine is from Valmet-"off the
shelf," Hewitt says-although the base ply is on
the top of the double fourdrinier. "We flipped

Paper360ยบ NOVEMBER/DECEMBER 2017

31



Table of Contents for the Digital Edition of Paper360 - November/December 2017

Setpoint
Over the Wire
Rebuilds and Conversions
Proud to be a Papermaker
The New Cascades
Operational Data Helps Mills Meet Challenges
Papermaking Best Practices with Vacuum-Dewatering Systems: Part 2
TAPPI Library is an Industry Resource
Managing the Decline of Graphic Paper Demand
TAPPI Journal Summaries
2017 PPI Awards Finalists
TAPPI News
ASPI News
Index of Advertisers
Paper360 - November/December 2017 - Intro
Paper360 - November/December 2017 - cover1
Paper360 - November/December 2017 - cover2
Paper360 - November/December 2017 - 3
Paper360 - November/December 2017 - 4
Paper360 - November/December 2017 - 5
Paper360 - November/December 2017 - Setpoint
Paper360 - November/December 2017 - 7
Paper360 - November/December 2017 - Over the Wire
Paper360 - November/December 2017 - 9
Paper360 - November/December 2017 - 10
Paper360 - November/December 2017 - 11
Paper360 - November/December 2017 - Rebuilds and Conversions
Paper360 - November/December 2017 - 13
Paper360 - November/December 2017 - 14
Paper360 - November/December 2017 - 15
Paper360 - November/December 2017 - 16
Paper360 - November/December 2017 - 17
Paper360 - November/December 2017 - 18
Paper360 - November/December 2017 - 19
Paper360 - November/December 2017 - 20
Paper360 - November/December 2017 - 21
Paper360 - November/December 2017 - 22
Paper360 - November/December 2017 - 23
Paper360 - November/December 2017 - Proud to be a Papermaker
Paper360 - November/December 2017 - 25
Paper360 - November/December 2017 - 26
Paper360 - November/December 2017 - 27
Paper360 - November/December 2017 - 28
Paper360 - November/December 2017 - 29
Paper360 - November/December 2017 - The New Cascades
Paper360 - November/December 2017 - 31
Paper360 - November/December 2017 - 32
Paper360 - November/December 2017 - 33
Paper360 - November/December 2017 - Operational Data Helps Mills Meet Challenges
Paper360 - November/December 2017 - 35
Paper360 - November/December 2017 - 36
Paper360 - November/December 2017 - 37
Paper360 - November/December 2017 - Papermaking Best Practices with Vacuum-Dewatering Systems: Part 2
Paper360 - November/December 2017 - 39
Paper360 - November/December 2017 - Managing the Decline of Graphic Paper Demand
Paper360 - November/December 2017 - 41
Paper360 - November/December 2017 - TAPPI Journal Summaries
Paper360 - November/December 2017 - 43
Paper360 - November/December 2017 - 44
Paper360 - November/December 2017 - 45
Paper360 - November/December 2017 - 2017 PPI Awards Finalists
Paper360 - November/December 2017 - 47
Paper360 - November/December 2017 - TAPPI News
Paper360 - November/December 2017 - ASPI News
Paper360 - November/December 2017 - Index of Advertisers
Paper360 - November/December 2017 - cover3
Paper360 - November/December 2017 - cover4
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