Paper-based packaging plays a critical role in our modern economy. Retail distribution and e-commerce supply chains depend on high-performance packaging for the products shipped nationwide and around the world. Manufacturers, farmers and logistics companies all rely on paper-based packaging to bring their products to market and satisfy the needs of their customers and consumers.
Our environment is fundamental to our quality of life. With the ever-increasing focus on recycling and the circular economy, Crossroads Paper is positioned to take a leading role in the production of new packaging materials from wastepaper. By repurposing the resources that exist within the cast-offs of daily life, Crossroads Paper will give new life to old materials, support economic growth, and preserve our nation’s forests far into the future.
Environmental protection is a critical part of the Crossroads Paper approach. From its reliance on recycled raw materials to its world-class water management systems, every part of the operation has been carefully designed to limit water usage and minimize carbon emissions, while serving the community’s recycling needs and protecting the region’s natural resources.
RECYCLED RAW MATERIALS
To transform used materials into beneficial new products, innovators need to identify markets for recycled products and then invest in modern technology to clean, process and convert those used materials.
Crossroads Paper has been designed from its inception to use 100% recycled fiber. Each step in the operation is based on the requirement that all raw materials are recycled. Other papermaking facilities source raw materials from trees, but not a single tree will be consumed at Crossroads Paper. Not one. By specifically and uniquely designing the operation to process only recycled fibers, everything at Crossroads Paper will be built from the ground up to make something new and useful out of something old and discarded. Recycling will not be an option at Crossroads Paper; it will be a way of life.
By carefully selecting and sourcing these recycled raw materials, Crossroads Paper will have the ability to control its production process and manufacturing specifications to ensure that its finished products meet the most demanding performance requirements. Years of recycling experience and a legacy of outstanding performance in addressing environmental issues will inform every step along the way.
Neighborhoods, local communities and government agencies will play a critical role in the success of the operation, as they are the key sources for the recycled raw materials to be collected for re-processing. Strong and mutually beneficial relationships with these stakeholders will contribute to the long-term strength of Crossroads Paper.
WATER RESOURCES
Whether for agricultural, industrial or residential use, water is a precious commodity in the community, and effective management of water resources is another foundation of Crossroads Paper.
Paper recycling requires process water, and successful operations are efficient in the use, processing and treatment of this important resource. By employing the most modern water-management systems, the volume of water required by Crossroads Paper will be far below the industry average.
Water required for the project will come from existing water rights, and all process water will be treated and cleaned prior to being returned to the local aquifer via rapid-infiltration basins (RIBs) installed on-site. By re-introducing this resource, total water consumption will drop by over 70% compared with existing agricultural uses, preserving available water for downstream users, farmers, and industry. In terms of water management, Crossroads Paper will be in a class by itself.
AIR QUALITY
Crossroads Paper subscribes to the highest possible standards of clean air. Because the operation will be built exclusively to produce recycled containerboard from recycled raw materials, pulping or bleaching processes common at other facilities will not be required. By avoiding these processes altogether, Crossroads Paper will eliminate the accompanying challenges they can bring to air quality.
ENERGY
Energy for the operation will be drawn from the existing power grid, and steam for the drying process will be generated using natural gas. No coal or biomass will be burned on-site.
ENVIRONMENT CONTROLS
Crossroads Paper benefits from the input of recognized recycling leaders with years of experience managing the environmental impact of similar operations.
Every step in the Crossroads Paper production process will be guided by U.S. Environmental Protection Agency (“EPA”) and Nevada Department of Environmental Protection (“NDEP”) regulations. In addition, discussions with local community members have been extremely beneficial in determining how best to configure the project so that it can exist in harmony with the local environment.
Recycling in the western United States takes many forms. While residential recycling exists in many communities, commercial, retail, and manufacturing segments of the economy make significant contributions to the recycling landscape and have done so for many decades. These collection systems contribute hundreds of millions of tons of paper fiber per year to recycling installations worldwide.
RESIDENTIAL
Curbside recycling programs collect wastepaper and used cardboard from homes and residences, and with the expansion of home delivery and e-commerce in recent years, have come to represent a significant portion of total recyclable materials. Voluntary drop-off systems can also provide a significant source of fiber, and Crossroads Paper will implement such a system in Winnemucca and Humboldt County to serve local residents.
COMMERCIAL & RETAIL
Grocery stores and other retail establishments collect and bale used cardboard, also known as old corrugated containers (OCC). Often these bales are shipped to distant destinations along the West Coast or overseas to be made into rolls of containerboard—the base material for making new cardboard boxes.
INDUSTRIAL, MANUFACTURING, AND DISTRIBUTION
Recyclable materials are also collected by industrial, manufacturing, and distribution companies that use corrugated materials in their own operations. As this sector has grown dramatically within the past 40 years, so has the need to identify and recover the many and varied recyclable materials contained within their waste streams.
PROCESSING
As collection programs have rapidly grown, there has naturally been a corresponding need to expand the capacity and number of local processing facilities. These facilities accept recyclable materials from the many regional collection programs and then sort, clean, shred, grind, bale and ship these resources to domestic and foreign markets.
Crossroads Paper will sit squarely in the center of the region it serves. As a result, recycling efforts of entire communities will benefit by having a consistent regional market for the materials recovered through these programs.
Papermaking plays an important role in our modern economy. American papermaking began with linen mills in the Northeast and then developed in the hardwood forests of Appalachia and the pine forests of the South. Eventually, paper production reached the Northwest, where it relied primarily on harvested timber.
Modern paper operations have increasingly turned to recycled materials for feedstock, and the trend toward greater use of recycled fiber is now reaching global markets. Plantation tree-farming has allowed many producers to lessen the impact of their operations on native forests, while recycled paper producers source the fiber they need from the paper-based products consumers dispose of each day.
Crossroads Paper will use the latest generation of equipment and technology, supplied by global experts who specialize in the manufacture, engineering and construction of papermaking machinery. Components of this equipment will be sourced both domestically and internationally, and the world-class expertise of regional companies will be involved in civil construction, infrastructure development and machinery installation. The result will combine the best resources the world and the local community can bring to this project.
STOCK PREPARATION
The first step in papermaking is the preparation of the raw materials. These raw materials consist of cellulose fibers, water, starch and other process chemicals. Fiber can be sourced from trees grown specifically for that purpose or harvested from available forest resources. Fiber can also be collected from recycling operations and processors. Regardless of origin, the cellulose fibers must first be softened and suspended in liquid.
Fibers are softened and prepared for processing by exposing them to heat, moisture and pressure. Depending on the origin of the fibers, the process might include additional process chemicals. In recycling-based operations like Crossroads Paper, the additional chemicals required are minimized, since the recycled paper that feeds the operation breaks down into its individual cellulose fibers much more rapidly than solid wood chips break down into individual fibers.
Fibers then pass through a refining process, where they are treated mechanically to prepare them to bond together more completely and thereby strengthen the final product. Once refined, the fibers are then diluted in process water before being placed onto the paper machine.
FORMATION
Paper is formed when diluted fibers are distributed onto a moving web and the process water is extracted using vacuum, pressure and heat. As the solution is delivered to the moving web from the highly advanced headbox, it contains less than 1% paper fiber, but by the end of the formation process, the paper web will be sturdy enough to sustain itself as it enters the press and drying sections of the machine.
DRYING
When the paper enters the press section of the machine, it is still extremely moist and not yet ready for its final use. It needs to be pressed and dried. Pressure is applied to the moving paper through a series of interconnected rollers and blankets that extract the excess moisture.
The drying section of the machine is composed of large, heated rollers that evaporate moisture, thereby aiding in the drying process and preparing the paper to be rolled at the end of the process.
Starch is also added to increase the strength of the finished paper, helping box makers and packaging customers protect their finished products.
CUSTOM REWINDING
When the papermaking process is complete, finished rolls will be just over 18 feet wide. To meet the needs of its customers, Crossroads Paper will rewind its master rolls to form smaller rolls according to the specific dimensions required by its customers. This custom rewinding process will ensure that Crossroads Paper can adapt its output to local, regional and international demand.
Environmental protection is a critical part of the Crossroads Paper approach. From its reliance on recycled raw materials to its world-class water management systems, every part of the operation has been carefully designed to minimize its water usage and carbon emissions, while serving the community’s recycling needs and protecting the region’s natural resources.
Packaging and shipping are essential to consumer satisfaction. Manufacturers, farmers, retailers, e-commerce companies and logistics providers all depend on packaging to move their products from many points of origin to limitless points of consumption.
Packaging materials, and the specific grades of containerboard to be produced at Crossroads Paper, are essential to ensuring that producers of all types of products can bring those products to market and delight their customers.
Over the past 100 years, box makers have perfected the blend of art and science that combines high-strength paper, demanding manufacturing tolerances and appealing graphic design to form efficient and cost-effective corrugated packaging.
CORRUGATION
The first step in the box making process is corrugation, where layers of paper are brought together to form high-strength cardboard panels. This process relies on heat, adhesive and starch to align the paper raw materials in the well-known wave patterns, or fluting, that are familiar to both consumers and packagers.
The specific patterns are determined by international standards and are known by a series of common designations (“A” flute, “B” flute, “C” flute, “F” flute) and combinations (“AB” flute, “BC” flute). Box customers specify these patterns based on the weight, distance traveled and climatic considerations for their individual shipments and provide those requirements to box manufacturers.
Box customers also specify the raw materials to be used in their packaging, and increasingly, these customers are requiring that their suppliers use recycled materials, the same materials to be produced at Crossroads Paper. The use of recycled containerboard is fundamental to the circular economy.
FINISHING
Once the containerboard has been formed using the desired flute configuration and cut to the appropriate size, graphics are printed on the corrugated sheets according to regulatory requirements, brand-building objectives and retailer needs.
Printed boxes are then cut into their final shape using specialized equipment and glued together to ensure product safety and security.
Printing on corrugated boxes can be extremely simple, using single-color graphics, or it can include highly complex, photo-quality imagery. Likewise, corrugated packaging can be extremely simple in its shape and configuration, or it can consist of complex geometric structures designed to highlight and merchandise products in ways that are attractive to consumers and other end users.
PERFORMANCE
Boxes serve many important functions throughout the supply chain. They must protect products from external forces and potential damage. They must communicate their content to both human eyes and electronic systems so that products can efficiently and rapidly reach their destinations. They must attract consumers and satisfy the desire for interaction and connectivity to those around them.
Sophisticated systems measure the physical performance of containerboard and finished boxes, and Crossroads Paper will meet or exceed the highest global performance standards for recycled containerboard.
It’s easy to find corrugated packaging in today’s economy. At every turn, more products are flowing through complex distribution channels to an ever-widening number of delivery points, and many of those products make that journey in corrugated packaging.
The world of packaging materials is a global marketplace. U.S. and Canadian firms compete alongside European, Asian and Latin American companies to supply the needs of consumers worldwide. Raw materials are sourced from rural forests and major cities. Papermaking takes place near metropolitan areas and in small towns. Boxes are produced in urban centers and in suburban communities, wherever packaging needs can be met. A box of bananas might have gotten its start at a facility in Georgia, and a box for a microwave oven might have begun its lifecycle in British Columbia. Each of these traditional production centers plays a vital role.
Crossroads Paper enters this market with a new and unique location, deep market knowledge and sophisticated operational technology. In previous decades, Nevada might have been overlooked for an operation of this type, but the regional infrastructure, skilled labor force, and transportation links to the world market make it a strategic choice.
Manufacturers, farmers, logistics companies, and shippers across the West will all benefit from this new investment in packaging materials. Add to that the recycling benefits for local governments, businesses and households, and it’s easy to see that this is a winning combination.
Crossroads Paper will also benefit from its association with CellMark, a leading global distributor of paper and cellulose fibers. Headquartered in Gothenburg, Sweden, and with more than 40 years of experience in the worldwide fiber market, CellMark will act as the exclusive sales agent for Crossroads Paper, bringing with it a broad network of commercial contacts and industry-leading expertise.
CellMark personnel will be co-located at the Crossroads Paper facility and will integrate directly with the operation’s production, shipping and distribution personnel. This close relationship will provide equally close coordination and ensure optimal service for customers throughout the region and beyond.
What will be the economic impact of this new project on the local economy?
The project will create several hundred new direct and indirect jobs with a total economic impact exceeding $1 billion over ten years.
How large is this new plant and how much recycled material will it process?
The plant is expected to produce approximately 1,000 tons of packaging paper per day and will be constructed on a site of approximately 400 acres.
Is this project being financed by private or public investment capital?
The project will be financed by private investment capital.
What will be the environmental impacts of having this new recycled containerboard facility?
The operation will be based on processing regionally generated recyclables. In addition, by eliminating excessive transportation, this local facility will dramatically reduce the greenhouse gas emissions from trucks that currently carry these materials across Nevada and out of state. In addition, local processing of recyclables will strengthen local recycling programs and keep useable materials out of local landfills.
Don’t traditional paper mills use a really large amount of water? As a naturally arid place, Nevada faces frequent droughts and water conflicts among western states. Won’t this new recycled containerboard facility put a strain on our already stretched water resources?
This project has been designed to operate with far less water than is typically used by traditional paper mill, and process water will be treated on-site before returning to the aquifer via rapid-infiltration basins (“RIBs”). Crossroads Paper will produce paper using available water resources within Humboldt County and the State of Nevada’s existing hydrologic infrastructure.
Traditional paper mills are known for using chemicals and discharging emissions that can pollute the surrounding area. What assurances or safety measures can you provide that this new facility will keep our community and environment safe?
Many traditional paper mills employ on-site pulping and bleaching, which can require significant chemical inputs. By limiting production to recycled materials and adding on-site water treatment, Crossroads Paper will dramatically reduce chemical usage and water consumption. The result will be a much cleaner process that will not emit unpleasant odors.
Will this new facility use recycled paper and corrugated boxes only from Nevada, or will recyclable materials be shipped into the market from farther away?
The western states provide abundant recycled paper and cardboard boxes to supply the facility. Much of this supply is currently shipped overseas for re-processing. Crossroads Paper will receive raw materials, by both truck and rail, from sources throughout the western region in sufficient volume to operate at optimal capacity.
With the growth of Amazon and other “direct-to-consumer” e-commerce, how will this new facility help with recycling so many more shipping boxes? How much of the facility’s input of recycled materials and paperboard will come from consumer recycling programs versus commercial retailers like Walmart, Target, etc.?
As consumers use more and more cardboard shipping boxes, the volume of boxes collected from homes and offices will continue to increase. While the overall share of materials sourced may change over time, the largest contributions of recycled fibers are expected to come from industrial, retail and other institutional sources, supplemented by home collections and drop-off sites.
Since China is cutting back on buying U.S. generated recycled materials, how will this new facility help address the over-supply of recyclables in the U.S. and locally?
Global demand for recycled materials is shifting as China and other Asian markets reassess their demand for recycled paper. By redirecting recyclable materials away from international markets and keeping them for domestic use, Crossroads Paper will be well-positioned to serve the expanding local need for packaging materials and lessen the dependence on foreign markets.
Why is this new plant ideally suited to the region? Why is it so unique?
Currently, U.S. paper production is concentrated in the Southeast, Upper-Midwest, and Pacific Northwest, but the growing economic output in the West requires shipping materials for agricultural products, manufactured goods, and logistics services. By bringing together modern production techniques, world-class equipment, and deep market knowledge, and positioning the operations in ideal proximity to end users, Crossroads Paper will become a significant source of recycled materials to a growing market.
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