Fiber-Based Solutions: Sustana mill optimization for dry bale production

photo from Paper360

“Sustana is a leading producer of top-quality fiber-based products and services, committed to sustainability and continuous improvement. Operating across North America with nine recovery facilities, two fiber recycling facilities, and a paper manufacturing facility, Sustana is a trailblazer in incorporating clean, renewable materials into everyday products.

Sustana manufactures premium, FSC® certified sustainable recycled fiber ideal for a range of applications. From food-grade packaging to printing and commercial paper and board, plus towel and tissue paper, their products embody both performance and environmental stewardship. Within their facilities in De Pere, WI, and Levis, QC, Canada, Sustana processes up to 2.2 million pounds per day of recovered paper in the form of sorted office paper, paper cups, aseptic and gable top cartons, and even release liner. This translates to a significant reduction in landfill space—over one million cubic yards per year. (See sidebar to read more about Sustana’s sustainability commitment.)

The De Pere facility, established in 1992, has specialized in wet lap fiber production. While producing 450 tons per day of quality fiber, the mill’s growth potential remained restricted due to manufacturing and transportation challenges of a product that was roughly 50 percent water. The answer? A capital project with a unique equipment source, making the most of every opportunity. The addition of dryer equipment at this facility marks a pivotal move to propel production into a new era within the recycled fiber market.

Sustana’s wet lap pulp already has a unique market: sustainable, 100 percent recycled fiber that is compliant with FDA standards for use in direct food contact packaging without the need for a barrier of any type. However, shipping wet lap is not economical, and in wet form the pulp has a limited shelf life. This project allowed Sustana to produce dry baled pulp that can be stored indefinitely and shipped anywhere in the world.

Sustana acquired the fluff drying equipment from Chetwynd, British Columbia, in September 2022. The Chetwynd mill had undergone a two-week shutdown in 2015, during which the decision was made to close the facility. At the time of closure, the drying system and presses were undergoing reconstruction and were at various stages of repair. The equipment remained disassembled and idle until Sustana stepped in to acquire it. Now, it stands as a testament to resilience and adaptability, ready to drive the De Pere operations forward.”

Quote from www.paper360-digital.com