Graphic Packaging's Waco Facility Nears Completion, Advancing Sustainable Packaging Production

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Graphic Packaging International is making significant strides in the construction of its state-of-the-art recycled paperboard manufacturing facility in Waco, Texas.

Just one year after the installation of the first steel beam, the company has begun machine installation, marking a crucial milestone in the project's development.

Announced in early 2023, this $1 billion investment represents Waco's largest economic development to date. The facility, spanning 640,000 square feet, is designed to meet the growing consumer demand for sustainable packaging solutions. With production set to commence in late 2025, the Waco site is poised to become a cornerstone of Graphic Packaging's sustainability strategy.

Michael P. Doss, President and CEO of Graphic Packaging, recently visited the site to assess progress. He emphasized the facility's importance to the company's Vision 2030 strategy, stating, "Bringing our Waco paperboard manufacturing facility to life is critical to our Vision 2030 strategy: to deliver the world's most innovative and sustainable consumer packaging".

The Waco facility incorporates cutting-edge technology, modeled after the company's K2 machine in Kalamazoo, Michigan. This new paperboard machine is expected to produce around 550,000 tons of coated recycled paperboard annually, significantly boosting Graphic Packaging's North American capacity.

Notably, the Waco site features three key enhancements that set it apart in terms of sustainability and circularity:

  1. A blended fiber line capable of repurposing 250,000 tons of recyclable scrap paperboard from Graphic Packaging facilities across the U.S.
  2. A horizontal drum pulper that can process up to 15 million paper cups daily into recyclable material.
  3. A co-generation plant that will allow the facility to generate its own energy, using heat and steam byproducts in the paperboard drying process

These features align with Graphic Packaging's commitment to improving the environmental footprint of its operations. Doss highlighted the company's significant investment in expanding renewable fuel and recycling capabilities.

The strategic location of the Waco facility, within 200 miles of major urban centers like Houston, Dallas, and San Antonio, provides ideal access to customers and suppliers. This positioning is expected to optimize the company's mill network and reduce production costs.

Graphic Packaging International is a leading provider of sustainable fiber-based packaging solutions, based in Atlanta, Georgia. With over 100 facilities worldwide, GPI specializes in folding cartons and foodservice packaging for various industries, including food and beverage.