Project Elevate involved the conversion of PM2 — formerly a coated freesheet machine — to the production of solid bleached sulfate board (SBS).
July 29, 2025 - Sappi North America today announced that it is delivering commercial product to customers following the completion of Project Elevate, the $500 million conversion and expansion of Paper Machine No. 2 (PM2) at its Somerset Mill in Maine.
Project Elevate involved the conversion of PM2 — formerly a coated freesheet machine — to the production of solid bleached sulfate board (SBS). PM2 now has the capacity to produce around 520,000 tons per year of SBS.
Qualification processes are being completed with a number of customers, and production will ramp up to full volumes through 2026.
The investment doubles PM2's production capacity and strengthens Sappi's position as a leader in sustainable packaging by transforming Somerset into one of the most advanced production sites for high-performance SBS (solid bleached sulfate) paperboard.
"This is a pivotal moment for Sappi North America," said Michael Haws, President and CEO. "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. The true success of this project lies in our people. Their precision, focus, and unwavering commitment to safety enabled us to complete a complex transformation, all while keeping the mill fully operational. This investment goes beyond machinery; it's about laying the foundation for long-term innovation, sustainable growth, and lasting impact."
As production continues to ramp up, this strategic investment is planned to deliver 520,000 short tons (approximately 470,000 metric tons) of annual capacity and expands Sappi's ability to produce a full range of high-performance SBS paperboard grades, including folding carton, food service board, and cups. This positions Sappi North America as a full-service SBS provider, enhancing its ability to support both domestic and global packaging customers with advanced technology that delivers superior product quality and consistency.
"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," said Kirk Ross, VP of Manufacturing. "With increased capacity and a focus on improved service, we're able to meet growing demand with greater speed, consistency, and responsiveness."
Sappi North America began the PM2 conversion in 2022, following the successful rebuild of PM1 in 2018. These upgrades demonstrate Sappi's commitment to modernizing its operations in ways that support both business growth and environmental responsibility.
"This conversion represents a major step forward in our global packaging strategy," said Steve Binnie, Chief Executive Officer of Sappi Limited. "It reflects our commitment to long-term growth and to broadening Sappi's portfolio of packaging solutions our customers need."
Headquartered in Boston, Massachusetts, Sappi North America, Inc., is a leader in converting wood fiber into superior products that are used worldwide. Sappi NA has a corporate office in Portland, Maine and mills in Skowhegan and Westbrook, Maine, Cloquet, Minnesota, and Matane, Quebec, along with a dedicated Technology Center and Sheeting Facility. Sappi NA, a subsidiary of Sappi Limited, employs approximately 2,100 people in the United States and Canada.
SOURCE: Sappi North America, Inc.