One year ago, Whakatāne Mill underwent a significant expansion following investment from key stakeholders. With a focus on future-proofing Whakatāne Mill for decades to come, key upgrades were made across multiple areas. From innovative technology to modern equipment, the upgrade was designed to boost our efficiency and improve product quality; while ensuring we maintained our commitment to sustainability.
Since the rebuild, Whakatāne Mill has made considerable progress not only in the quality of products we are able to provide our customers but also in our sustainability goals. The changes have positively impacted our environmental footprint and production process; energy consumption per tonne of board has reduced by 30%, 200 metric tonnes of plastic wrap has been eliminated, and water consumption has reduced by 20%.
Read on to learn how we achieved this, and more, as we reflect on key milestones achieved in the past year.
Our commitment to sustainability
At Whakatāne Mill, sustainability has always been at the heart of our operations. A year after our expansion, our commitment to reducing environmental impact has led to measurable, positive changes across the board.
Reducing waste and conserving resources
One of our most intuitive upgrades was moving away from plastic wrapping in favour of recyclable paper packaging. As leaders in fibre-based products, this was a long overdue change for us, reducing our plastic consumption by 200 tonnes per annum. We know our packaging is a competitive, cost-effective upgrade to plastic, and now we demonstrate that to our customers first-hand with every delivery.
Water conservation has been another key area of focus for the Whakatāne Mill team. By nature, board production requires large quantities of water, both in the manufacturing and cooling processes. While water is a renewable resource, it must undergo a treatment process in order to cycle back into the regional water system. By upgrading our production systems, we have managed to reduce water consumption taken from the Whakatāne River by 2 million litres per day, which adds up to a staggering 730 million litres saved annually.
Improving energy efficiency
Energy efficiency has always been a key priority within Whakatāne Mill from a financial and environmental standpoint. Upgrading our Groundwood Mill with diamond-tipped stones has reduced energy consumption by 20%. Meanwhile the installation of the extended nip shoe press and upgrades in our drying section, double felting system and upgraded the steam and condensate system, has led to a 30% reduction in the energy required to dry each tonne of paper.
Our upgraded heat recovery system has also helped us capture and reuse 20% more heat in the drying section, leading to a noticeable reduction in gas consumption. By making the most of the energy we use, we can reduce how reliant we are on non-renewable gas supplies, further improving our sustainability.
Best of all, these upgrades have not been at the detriment of our products. In fact, we can produce higher-quality folding boxboard than ever before, all while working cleaner and greener. Sustainability is not just a goal for us – it is part of how we operate every day.
Improvements to product quality and customer experience
One year after our expansion, Whakatāne Mill customers are seeing a range of improvements to the quality and performance of our folding boxboard. With total production capacity boosted by an additional 50,000 metric tonnes, we have increased our ability to meet global demand while maintaining the high standards that our customers have come to expect.
One of the key benefits of the upgrade has been to our coating section, which has resulted in a smoother print surface across all nine of our folding boxboard lines. This improvement allows for sharper, more vibrant printing, which creates a more professional product for our customers. Alongside this, the overall bulk of our products has increased, providing on average a 7% yield gain across all grades. This means we can create more packaging with less fibre, helping our products remain competitive on price, while also being environmentally friendly.
Using state-of-the-art technology, we conduct advanced quality control to ensure consistency across every batch, so customers can rely on the same level of product on every order. Additionally, we are excited to offer added value options through substrate coating, set to launch in 2025. This new option will give customers even more flexibility for their packaging needs.
Listening to our customers and investing in the latest technologies, we have delivered a product range that excels across every measure of success. Whether it is smoother printing, improved durability, or confidence in consistency, Whakatāne Mill is committed to customer-focused products and quality.
Expanding our reach to over 90+ destinations
Whakatāne Mill has significantly expanded its international footprint over the last year, cementing our place as a key player in the folding boxboard market. In the 12 months from August 2023 to August 2024, we have increased our delivery destinations from 59 to 92; an increase of 55% in just one year.
Our growth reflects the demand for high-quality, sustainable packaging solutions worldwide. More businesses are seeing the benefits of environmentally friendly product packaging, which is helping us reach new markets. With our products being used by diverse industries around the world, our reputation as a trusted global supplier is being reinforced.
While our reach has grown, our commitment to our customers remains unchanged. Whether they have been with us for decades or are new to the fold, every customer can expect the same level of service, reliability, and quality that sets Whakatāne Mill apart. And, as we continue to expand, we will ensure our growth is built on the same values of sustainability, quality, and trust that have guided us from the start.
What the year ahead has in store for Whakatāne Mill
One year on, Whakatāne Mill has well and truly demonstrated a return on investment to our partners. Through strategic investments in technology and a clear focus on environmental responsibility, we have reduced our plastic consumption, cut water and energy use, and improve the quality of our products; all while expanding into new markets.
Looking ahead, we will continue the work to create innovative, high-quality folding boxboard grades that meet our customers’ needs and our sustainability goals. We will also continue to evolve, improve, and endeavour to stay at the forefront of the global packaging industry.
