Graphic Packaging Starts Up Kalamazoo’s New K2 Coated Recycled Board Mill, TAPPICon24

In early 2022, Graphic Packaging international (GPI) started up a new $600 million state-of-the-art “K2” papermaking line in Kalamazoo, Michigan —the first North American coated recycled board mill constructed in three decades. K2 produces over 1,500 tons/day of the highest quality 3-ply coated recycled board. Simultaneously, the company shut down four multiply cylinder forming machines within the GPI mill system, so the total production capacity was net neutral.

The expansion incorporates modifications to an effluent treatment plant, steam plant, recycled fiber plant, and a new 230” trim 3-ply paper machine with curtain coating, automated winder, roll handling and expanded roll warehouse. The project focused on overall mill production efficiency as well as environmental and sustainability aspects, including reduction in greenhouse emissions, water usage and energy consumption per ton. The investment takes us a step closer to a future circular economy without foam cups, plastic clamshell containers or six-pack plastic rings. This paper introduces the story behind the new mill project, and reviews project details and mill experiences after the startup.

The success of K2 is founded on a culture of teamwork developed and embodied by the project managers, engineers, suppliers, and operations employees who worked tirelessly for two years prior to startup. Through this effort we were able to achieve design capacity within the first six months of production. An investment of over $2MM in training was instrumental in preparing a diverse workforce of newly hired operations and maintenance technicians to operate the mill safely and effectively. A special emphasis was placed on forming in-house process control and automation expertise to achieve a vertical startup and sustained continuous improvement.

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