Rewriting Paper 
Sustainability

Introduction:

In 2013, American Eagle Paper Mills launched the Phoenix Initiative, a bold endeavor aimed at reinventing the mill’s critical infrastructures with a primary focus on environmental efficiency. Completed in August 2016, the Phoenix Initiative has not only transformed the operations at American Eagle Paper Mills but has also positioned the company as a true environmental leader in the manufacturing of 100% recycled paper.

Situated in Tyrone, PA, American Eagle Paper Mills boasts a rich history dating back to its establishment in 1880. Once operated by MWV (formerly Westvaco), the mill had seen significant changes over the years. Prior to American Eagle Paper Mills stepping in, the facility housed five paper machines. However, the elaborate energy infrastructure was deemed larger than necessary for just the two machines in operation, leading to systemic inefficiencies

Initiative and Implementation:

The Phoenix Initiative commenced with a comprehensive redesign of the mill's energy system. This included the installation of new power frequency converters and power factor correction equipment, along with the implementation of high-efficiency steam generation and distribution systems. Additionally, the initiative involved the conversion to locally sourced and low-cost Pennsylvania grid power, reducing reliance on non-renewable energy sources.

The completion of the Phoenix Initiative in August 2016 marked a significant milestone for American Eagle Paper Mills. The $8 million investment resulted in dramatic environmental improvements. Purchased energy efficiency improved by 33.7%, leading to a notable 67.7% annual reduction in greenhouse gas emissions. Moreover, the initiative facilitated an 18.1% reduction in process water usage and an impressive 83% decrease in water withdrawal from local watersheds.

One of the most remarkable achievements of the Phoenix Initiative was the banning of coal usage at the mill. The strategic move majorly contributed to a cleaner environment and eliminated the transportation of 70,000 tons of coal and 10,000 tons of coal ash through the town of Tyrone, PA, enhancing the safety and well-being of the local community.

Celebration and Recognition:

American Eagle Paper Mills celebrated the successful completion of the Phoenix Initiative with an event in September 2016. With over 150 guests in attendance, including local politicians, business leaders, mill employees, and the Phoenix Initiative team, the group gathered to commemorate the huge accomplishment. Mill leadership praised the dedication and ingenuity of the team, emphasizing that much of the project was engineered and executed by the mill's own employees.

The achievements of the Phoenix Initiative garnered significant attention from both local and national media outlets. Stories highlighting the project's environmental savings and its impact on the community were widely covered and praised. This positive publicity not only enhanced the reputation of American Eagle Paper Mills but also underscored the company's commitment to sustainability and innovation in the paper manufacturing industry.

In Conclusion

The Phoenix Initiative exemplifies American Eagle Paper Mills' dedication to environmental stewardship and continuous improvement. By reinventing its critical infrastructures with a focus on environmental efficiency, the company has achieved substantial reductions in energy and water usage and eliminated its reliance on coal, significantly contributing to a cleaner and safer environment for the community. Moving forward, American Eagle Paper Mills remains steadfast in its commitment to sustainability, setting new standards for paper production in the industry.