Water: A Necessary Ingredient in Paperboard Production

A large volume of water goes into making paperboard. At PaperWorks, sustainability is at the core of what we do and reducing water waste is a top priority.

One of our key priorities has been to produce our high-quality MasterWorks Ultra 100 Whiteback, while using less water without sacrificing it quality or appearance.

The Challenge

Our MasterWorks Ultra 100 Whiteback is a premium paperboard grade made from 100% recycled content, yet it looks and performs like virgin paper. To maintain that high quality requires exceptionally clean water during production.

Relying on fresh city water posed the following three challenges:

• High water consumption
• Energy costs to heat the water
• Excess water waste strained our infrastructure

With water conservation a company priority, we knew we needed a smarter approach.

Our Solution

We implemented a closed-loop water recycling system to optimize the use of recycled water from our wastewater treatment process.

Here’s How It Works:

• Hot process water (~125°F) is captured, filtered, and redirected back into production.
• Inline screens remove solids and maintains water purity
• More high-quality fiber is preserved reducing overall waste

It took many months of planning, cross-functional teamwork and a phased approach to make this happen and ensuring there was minimal production downtime.

Results That Matter

This innovation did more than just cut water waste:

• Water Savings: Over 15 million gallons are saved annually, reducing water use by 300,000 gallons per day while producing MasterWorks Ultra 100 Whiteback.
• Energy Efficiency: 10 billion BTUs are saved annually since less energy is needed to heat the water.
• Less Waste: Diverting 15,000 tons of fiber from landfills each year.
• Improved Productivity: Consistent water temperatures have stabilized machine performance, reducing downtime and safety risks.
• Workforce Impact: Enhanced training to ensure system efficiency, reinforcing a culture of continuous improvement.

Overall Effect

Water conservation isn’t just about lowering costs, it’s about responsible manufacturing and environmental stewardship.

By reducing our reliance on municipal water supplies, we’ve strengthened our role as a responsible community partner and aligning with our environmental stewardship goals.