DS Smith upgrades Lucca Paper Mill in Porcari, Italy

Leading sustainable packaging manufacturer will install paper machine and stock preparation plant with enhanced production and environmental benefits, while decommissioning PM1
Site will provide a range of paper grades to support the demand for innovation in sustainable packaging

DS Smith, the leading provider of sustainable packaging solutions, announced it will install a new state-of-the-art production line in its Porcari (Lucca) paper mill while decommissioning PM1 after 50 years of service. The new paper machine will provide a range of environmental benefits as well as produce a range of paper grades for the FMCG and e-commerce sectors the company serves.

The Porcari paper mill, which is among the largest in Italy in the sector and employs around 200 people, will provide light-grammage paper and board for food & beverage, FMCG, and e-commerce customers. The new paper machine will be placed in an available area between the current machines and CHP plant and will produce up to 450,000 tonnes of a new range of products, mainly brown liner and medium lightweight grades recycled paper per year once fully operational. The start-up of the machine is planned for mid-2025. At that time, the PM1 machine which produces around 150,000 tonnes per year will stop.

The site will use state-of-the-art technology which will lead to a significant increase in the paper mill's environmental performance, with a 22 per cent reduction of CO2 emissions per ton of paper produced and a 20 per cent reduction in specific water use, including a greater use of surface water instead of groundwater.

“The fibre-based packaging market will continue to grow significantly in the coming years and we are pleased to play our part in helping many of DS Smith’s customers transition to a circular economy".

The Porcari site will be under the supervision of the paper mill's General Manager Massimo Basta, who has extensive experience in the paper industry, with a particular focus on paper made from recycled raw material.

"Thanks to the use of state-of-the-art technology, this will be done with the utmost respect for the environment optimizing the use of energy and water. With this project, Lucca mill will continue to sustain the circular economy for future generation”

DS Smith has several production facilities in Italy located mainly in the North and Center of the country, employing about 1,000 people. The facility will support the Castelfranco Emilia packaging facility by providing it with recycled paper as part of its closed loop operating model, in support of the transition to a circular economy as part of its Now & Next Sustainability Strategy.

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