Three years after converting its Kingsport, Tennessee, mill to 100% recycled containerboard production, the operation has become a cornerstone of Domtar’s packaging business, supported by strong customer partnerships and consistent product performance.
The company entered the containerboard market in 2023 following a more than $600 million investment to transform the former freesheet paper mill. Today, Kingsport produces two premium recycled containerboard grades: Performance Linerboard and Performance Medium, both used in the manufacture of corrugated packaging for applications ranging from food and beverage products to e-commerce, electronics and automotive parts.
According to Domtar, advances in recycled papermaking technology have significantly changed perceptions of recycled containerboard. Its products offer a consistent warm brown appearance and enhanced performance characteristics compared with earlier recycled grades, which were often associated with lower strength and a dull grey appearance.
The improved strength characteristics of Kingsport’s products support lightweighting strategies, allowing corrugated converters and brand owners to reduce basis weights while maintaining packaging performance. By using less fiber, manufacturers can lower material consumption, reduce transportation requirements and decrease logistics costs. In markets where Extended Producer Responsibility (EPR) programs apply, lighter packaging can also help reduce associated fees.
A key element of the Kingsport business model is its reliance on recovered fiber. The mill processes approximately 660,000 tons of recycled fiber annually, primarily old corrugated containers (OCC) sourced through municipal recycling programs and supply partnerships with retailers and manufacturers.
Domtar describes the operation as part of a closed-loop recycling system in which recovered corrugated packaging is returned to the manufacturing process and converted into new containerboard products. As of Earth Day 2026, the company reported having processed more than 1.5 million tons of recyclable material into new containerboard since the mill began operating as a packaging facility.
The transformation has also delivered significant environmental benefits. Compared with its previous operation as a virgin freesheet mill, the recycled containerboard process uses minimal chemicals, approximately 70% less water and about 50% less energy, according to the company.
Three years after its conversion, Kingsport remains central to Domtar’s packaging strategy. The company continues to focus on premium recycled containerboard, circularity and material performance as it continues to expand its presence in the North American corrugated packaging market.
Domtar is a leading North American provider of fiber-based products, including pulp, paper, packaging and wood products. The company operates an extensive network of manufacturing facilities across North America and focuses on delivering sustainable, high-performance solutions to a wide range of markets.
