Sappi concludes $500m expansion project at Somerset Mill in Maine, US

Sappi North America has announced the completion of Project Elevate, which involved a $500m investment to convert and expand Paper Machine No. 2 (PM2) at its Somerset Mill located in Maine, US.

This development comes as a response to the growing demand for quality, fibre-based sustainable packaging solutions.

The company is now poised to deliver commercial products to customers, with qualification processes underway and full production volumes expected by 2026.

The expansion doubles the production capacity of PM2 and transforms Somerset into an advanced site for producing solid bleached sulfate (SBS) paperboard.

Sappi North America president and CEO Michael Haws said: “With PM2, we have delivered the largest rebuild in our company’s history, doubling the machine’s capacity and positioning Somerset as a leader in sustainably manufactured paperboard.

“This investment goes beyond machinery; it’s about laying the foundation for long-term innovation, sustainable growth, and lasting impact.”

As Sappi North America gears up for full-scale production, the investment is expected to yield an annual capacity of approximately 470,000 tonnes (t) of SBS paperboard.

This includes a range of high-performance grades suitable for folding cartons, cups, and foodservice boards.

The company will now be able to support both domestic and international packaging customers with the latest technology.

Sappi North America manufacturing vice-president Kirk Ross said: “Product from the new machine is now commercially available, delivering the same high standards of quality and performance our customers expect, while expanding our range of applications.

“With increased capacity and a focus on improved service, we’re able to meet growing demand with greater speed, consistency, and responsiveness.”

The PM2 conversion began in 2022, after the PM1 rebuild in 2018.

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