Domtar's Nekoosa mill has launched a new on-site precipitated calcium carbonate (PCC) plant, a collaborative project with Omya, addressing a critical supply chain challenge.
The new plant, operational since September 2024, resolves issues stemming from a 2020 regional PCC plant closure. Previously, the Nekoosa mill, along with Domtar's Rothschild facility, relied on a distant supplier, leading to increased costs and environmental impacts.
"Domtar had to adapt to these sudden changes in availability and cost of its PCC supply," said Kurt Mehlberg, Quality Solutions Manager. PCC constitutes up to 25% of the final paper sheet, making its consistent supply crucial.
To overcome the logistical hurdles, Domtar and Omya partnered to build a 27,500 dry-ton-per-year PCC plant within the Nekoosa mill's existing footprint. The plant, designed, owned, and operated by Omya, will supply PCC to both Nekoosa and Rothschild mills, as well as external customers.
The project involved significant capital investment from both companies for engineering, construction, and utilities. "This investment demonstrates our commitment to supporting the paper industry by providing sustainable, high-quality solutions," stated Marty Sheehan, Omya’s North American sales director.
The new plant offers numerous benefits, including a 15,000-short-ton annual reduction in Domtar's carbon footprint by reducing transportation by over 1,180,000 miles and reusing carbon dioxide from the mill's lime kiln and recovery boiler exhaust stacks.
Operational efficiencies will also improve, including enhanced PCC utilization, increased flexibility in paper machine scheduling, and maximized PCC usage for innovative grade development. Economically, the plant strengthens the mills' cost competitiveness and ensures a stable supply.
"By executing this high-ROI, three-year project with a strategic partner, Nekoosa now has an unlimited supply of PCC on-site," said Jason McCauley, Nekoosa mill general manager. The project exemplifies Domtar's values of collaboration and entrepreneurship, turning a challenge into a sustainable and efficient solution.
Domtar’s Nekoosa Mill, located in Nekoosa, Wisconsin, produces high-quality paper products, including printing, writing, and packaging materials. As part of Domtar, under Paper Excellence, the mill is committed to sustainability and innovation, using advanced technologies to meet industry demands while reducing environmental impact. It plays a key role in Domtar's mission to lead in renewable resource-based production.
