A Century of Innovation and Sustainability: Celebrating 100 Years of Kemsley Paper Mill
From its inception in 1924, Kemsley has grown from strength to strength, becoming the largest mill for recycled papers in the UK, and the second largest in Europe. As we mark the centennial of Kemsley Paper Mill, we reflect on our journey of innovation, growth, and commitment to sustainability.
From Humble Beginnings to Industrial Giant
Founded in 1924 by Frank Lloyd, Kemsley Mill began its life with a mission to produce newsprint. At the time, it housed the world's largest paper machines, a testament to the mill's ambitious foundations. By the mid-20th century, Kemsley had expanded under the ownership of Bowater’s, increasing output significantly and setting the stage for decades of industrial prowess.
The 1970s marked a significant diversification as Kemsley started producing corrugated case materials and fine papers. This was driven by the addition of a pulp mill designed to produce semi-chemical fluting. The introduction of the 'Manchester Former' on PM3 enabled the mill to excel in producing corrugated case liners, further broadening its manufacturing capabilities.
In the 1980s, a management buy-out led to the site's split, focusing on refining the operations for which the mill had become best known. This era also saw the beginning of DS Smith’s association with Kemsley, eventually leading to full acquisition in 2008.
Under DS Smith, Kemsley underwent significant investments, including the rebuild of PM6 and PM3. This ensured a long and commercially successful future as a cutting-edge paper mill driven by modern technology and innovation.
A New Era of Sustainability and Biodiversity
By 2012, Kemsley had begun to work towards more sustainable production processes. In 2015 Kemsley’s award-winning Reject Processing Centre launched, resulting in over 12,000 tonnes of ragger rope being diverted from landfill annually, as well as 6,000 tonnes of fibre recovery from pulper rejects.
In 2018, its efforts to harness renewable energy saw the introduction of an Anaerobic Digester, which recovers and cleans gas produced from waste, injecting it into the National Grid.
By 2020, an Energy from Waste plant that Kemsley takes power from in the form of steam, became commercially operational. This initiative complements the mill's waste management strategy and helps it to power operations sustainably.
DS Smith also launched the 'Now and Next Sustainability Strategy' in 2020, which focused on driving the transition to a low carbon, circular economy. At Kemsley Mill, this strategy prompted numerous initiatives aimed at enhancing environmental practices and promoting sustainable growth, including a number of site-led biodiversity projects.
2022 saw DS Smith and energy provider E.ON working together to unveil a state-of-the-art combined heat and power (CHP) plant, which reduces CO2 emissions by 36,000 tonnes a year. The mill's efforts in recycling, waste management, and energy efficiency are direct responses to the global calls for sustainability and DS Smith's commitment to the circular economy.
Embracing Digital Transformation
The paper industry has been changing over the last couple of years and it’s very good to see that Kemsley has captured state-of-the-art technology to drive the sustainability front by reducing our carbon footprint, waste and water.
Niels Flierman
Managing Director, Paper and Recycling
In recent years, Kemsley Mill has seen a significant leap in digitalisation. In 2021, the mill adopted Trimble’s data mining platform, Wedge, enhancing our production processes with advanced data visualisation and manipulation tools.
Similarly, the investment in Automated Guided Vehicles (AGVs) revolutionised operations at Kemsley’s fully automated warehouse. These electric vehicles handle tasks such as collecting and storing paper reels, optimising efficiency and reducing emissions.
Kemsley Paper Mill today
Boasting an annual production capacity of approximately 830,000 tonnes, Kemsley currently offers customers one of the widest choices of finished paper products available, including corrugated case materials, speciality papers and kraftliners.
Primarily, its products are used in board and packaging, while its speciality papers are used across a variety of industries including construction, printing, food manufacturing, packaging, stationery supplies and education.
Through continuous investment in advanced papermaking technologies, Kemsley Mill produces the highest quality of paper products, while ensuring they are all 100% recyclable and sustainably sourced.
In this centennial year, a £48M investment to Kemsley’s fibre preparation line will maximise the use of materials in the recycling process and reduce water usage and energy consumption. This will drive improved efficiency, sustainability and reliability.
Kemsley is further demonstrating its dedication to sustainability and promoting the circular economy through the launch of its brand-new Recyclability Evaluation Service. Based at its state-of-the-art Repulpability Laboratory the service offers a comprehensive assessment of fibre-based packaging recyclability, providing detailed reports and recyclability scores and pinpointing areas for improvement. Additionally, by offering customised solutions, including extra testing and expert consultations, the service will help clients enhance their packaging designs to improve the recyclability of their products and keep fibre in use for longer.
A Century Forward
As Kemsley Paper Mill celebrates its 100th anniversary, DS Smith stands proud of its past achievements while eagerly embracing a sustainable future. Through a continued investment in technology and commitment to enhancing the environment, Kemsley aims to maintain its legacy as a pioneer in the paper industry for many more years to come.
Kemsley is one of our principal assets in the group and it’s been wonderful to see the development over many years. Seeing all the work and the commitment from everybody at Kemsley has made it such a special site. It’s delightful to be a part of it.
