Sappi launches North America’s most advanced paper machine
$500 million investment at Somerset Mill expands Sappi’s leadership in high-end paperboard for food, beverage, and consumer packaging.
In response to rising demand for premium, fiber-based sustainable packaging solutions, Sappi North America announced the commercial availability of products following the completion of Project Elevate. This strategic $500 million investment involved the conversion and expansion of Paper Machine No. 2 (PM2) at the Somerset Mill in Maine. Customer qualification processes are currently underway, with full production capacity expected to be achieved gradually through 2026. The project doubles PM2’s production capabilities, positioning Somerset Mill among North America’s most advanced production facilities for high-performance solid bleached sulfate (SBS) paperboard and reinforcing Sappi’s leadership in sustainable packaging.
“This is a pivotal moment for Sappi North America,” stated Michael Haws, President and CEO. “With PM2, we completed the most extensive rebuild in our company’s history, doubling production capacity and elevating Somerset as a benchmark for sustainably produced paperboard. The true success of this endeavor lies with our dedicated workforce. Their meticulousness, determination, and uncompromising attention to safety have been instrumental in executing this complex transformation without interrupting ongoing mill operations. This significant investment represents more than equipment upgrades; it establishes a robust foundation for future innovation, sustainable expansion, and enduring market impact.”
Once fully operational, the newly upgraded PM2 is projected to provide an annual production capacity of 520,000 short tons (approximately 470,000 metric tons). This will considerably enhance Sappi’s ability to offer a comprehensive portfolio of SBS paperboard products, including folding cartons, food service boards, and cups. Consequently, Sappi North America becomes a complete SBS solutions provider, better positioned to meet the evolving needs of domestic and global customers with consistently high-quality, technologically advanced products.
“Commercial production from the new PM2 meets our consistently high standards of quality and performance expected by our customers, simultaneously expanding the variety of product applications,” remarked Kirk Ross, Vice President of Manufacturing. “Increased production capacity combined with enhanced customer service enables us to address rising market demands promptly and effectively, ensuring optimal responsiveness and consistency.”
The conversion of PM2 commenced in 2022, building on the successful overhaul of PM1 completed in 2018. These strategic upgrades underscore Sappi’s ongoing dedication to modernizing operations, supporting sustained business growth, and demonstrating a steadfast commitment to environmental responsibility.
“This significant investment marks a crucial advancement in our global packaging strategy,” emphasized Steve Binnie, CEO of Sappi Limited. “It embodies our dedication to sustained growth and reinforces our objective to diversify and strengthen our packaging solutions portfolio, ensuring alignment with evolving customer requirements.” With Project Elevate now complete, Sappi has further strengthened its leadership position in the high-end paperboard sector, reaffirming its ongoing investment in U.S.-based manufacturing capabilities, technological innovation, and the sustainable packaging industry’s future.
