Paper360 - November/December 2017 - 30

millwise | PACKAGING

The New Cascades
After meeting ambitious startup targets, Greenpac has set itself
and its employees up for long-term success.
GRAEME RODDEN

About four years to the day after
startup, Paper360° visited Cascades' Greenpac
mill in Niagara Falls, NY, to find a smoothly
running, efficient operation.
The 2016 PPI Mill Manager of the Year,
Murray Hewitt, justifiably shows off the company's largest investment ever: a 1,500 tpd linerboard machine that uses 100 percent recycled
furnish. The project can be considered a "greenfield/brownfield" project, Hewitt notes, as there
was a Kimberly-Clark mill on the site previously,
but Greenpac is totally new. Cascades also operates an adjacent medium mill and some services
are shared.
The US$460 million project started as the
brainchild of Cascades' executives around 2007.
Previously, Cascades was known as a company
that purchased closed or distressed assets, refurbished them and made them profitable. This was
to be the first mill it would build "from scratch."
"This is the new Cascades," Hewitt declares.
"We are looking at a mill viable for the next
50 years."
LOCATION, LOCATION
Why the world-famous Niagara Falls
region? As noted, Cascades operated the
medium mill next door and could share the
effluent treatment system. And, it had already
purchased the land.
Despite the tourism money from the falls
a couple of miles away, the region's economy
was not good. It was probably more known
for the infamous "Love Canal" toxic chemical
catastrophe. Therefore, the government of New
York targeted the upstate New York area for
economic renewal, promising to spend US$1
billion (the "Buffalo Billion," as it came to be
known). Incentives were available for power
and employment. Also, a nearby Covanta
chemical plant would be able to provide steam
to the new mill. Finally, the building of a linerboard mill would bring Cascades close to a
50:50 split in terms of geographical production
(US:Canada) and product (liner:medium).
30

Paper360º

Thus, the stage was set. The team broke
ground on September 15, 2011, and set an
ambitious startup target of being on reel in
22 months. The first stock was made by June
2013. Stock was on the wire in early July. To cap
it off, the sheet was on the reel July 15, 2013.
Hewitt himself joined Cascades on June
25, 2012, just after the first dryer can was
installed, which is always the first part of a new
paper machine to be put in place. Hewitt had

started his career with Abitibi-Price in Grand
Falls, NL, in 1984. He later joined Atlantic
Packaging's newsprint startup in Ontario in
the 1980s before moving to the US in 1999,
where he worked at several mills across the
South for what was then Bowater Inc.
Hewitt says a mild winter during construction helped the mill meet its goal. But,
he adds, "The challenge was that it was the
first big project of its type for Cascades and

Mill Manager Murray Hewitt shows off Greenpac's 1,500 tpd linerboard machine.

Greenpac's "greenfield/brownfield" mill in Niagara Falls, NY.

NOVEMBER/DECEMBER 2017

www.tappi.org


http://www.tappi.org

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
https://www.nxtbook.com/naylor/PPID/PPID0020
https://www.nxtbook.com/naylor/PPID/PPID0019
https://www.nxtbook.com/naylor/PPIS/PPIS0218
https://www.nxtbook.com/naylor/PPIS/PPIS0118
https://www.nxtbook.com/naylor/PPIS/PPIS0617
https://www.nxtbook.com/naylor/PPIS/PPIS0517
https://www.nxtbook.com/naylor/PPIS/PPIS0417
https://www.nxtbook.com/naylor/PPIS/PPIS0317
https://www.nxtbook.com/naylor/PPIS/PPIS0217
https://www.nxtbook.com/naylor/PPIS/PPIS0117
https://www.nxtbook.com/naylor/PPIS/PPIS0616
https://www.nxtbook.com/naylor/PPIS/PPIS0516
https://www.nxtbook.com/naylor/PPIS/PPIS0416
https://www.nxtbook.com/naylor/PPIS/PPIS0316
https://www.nxtbook.com/naylor/PPIS/PPIS0216
https://www.nxtbook.com/naylor/PPIS/PPIS0116
https://www.nxtbook.com/naylor/PPIS/PPIS0615
https://www.nxtbook.com/naylor/PPIS/PPIS0515
https://www.nxtbook.com/naylor/PPIS/PPIS0415
https://www.nxtbook.com/naylor/PPIS/PPIS0315
https://www.nxtbook.com/naylor/PPIS/PPIS0215
https://www.nxtbookmedia.com