Green Bay Packaging (GBP), one of the United States’ largest and most vertically integrated fiber-based packaging companies, has launched a landmark investment exceeding $1 billion into modernizing and expanding its Arkansas Kraft paper mill in Morrilton, Arkansas. Known as Project PowerPack, this multi-year initiative broke ground in June 2025 and is slated for completion in the first half of 2028.
At a time when many mills are closing or reducing capacity, GBP’s expansion represents a counter-cyclical strategic investment — doubling production capacity while setting new standards in sustainability and energy efficiency.
About Green Bay Packaging
| Metric | Value |
| Founded | 1933 |
| Headquarters | Green Bay, Wisconsin, USA |
| Total Facilities (USA) | >40 corrugated, folding carton, label, and integrated mill sites |
| Employees | ~4,500 nationwide |
| Primary Markets | E-commerce, retail, food & beverage, industrial |
| Mill Types | Kraft paper (linerboard + medium), recycled containerboard |
Green Bay Packaging’s vertically integrated model — combining pulp, paper, and corrugated converting — gives the company strong control over raw materials, pricing stability, and product quality.
Arkansas Kraft Mill: Production Today vs. After Project PowerPack
The Arkansas Kraft mill produces critical components of corrugated board:
- Kraft linerboard: top and bottom layers of corrugated board
- Corrugated medium: the fluted center layer
The mill uses both virgin fibers and recovered fibers to feed integrated paper production.
Production Capacity Comparison
Current vs. Future Annual Output (Approximate Tons)
| Product | Current Capacity | Future Capacity |
|---|---|---|
| Kraft Linerboard | ~ 400,000 tpa* | ~ 850,000+ tpa* |
| Corrugated Medium | ~ 200,000 tpa* | ~ 400,000+ tpa* |
| TOTAL Capacity | ~ 600,000 tpa* | ~ 1,250,000+ tpa* |
*Note: exact current capacities are not publicly disclosed. Estimates are indicative and based on industry ranges and available reporting.
*Note: exact current capacities are not publicly disclosed.
Estimates based on industry production ranges and GBP reporting.
💡 Key Takeaways
- After Project PowerPack, total capacity could more than double.
- Kraft linerboard output scales to support both GBP’s own converting plants and external customers.
Sustainability & Technology Upgrades
Project PowerPack delivers more than just scale:
| Upgrade | Purpose |
| New Recovery Boiler | More efficient steam/recovery cycle |
| Biomass Boiler | Lower carbon fuel source |
| 40 MW Electric Turbogenerator | ~90% of mill’s electricity generated on-site |
| Reductions in Scope 1 & 2 GHG | Strong sustainability performance |
| 300 Acres for Future Expansion | Long-term site growth |
These investments enhance energy efficiency, environmental performance, and overall operational resilience.
Strategic Importance for GBP and the Industry
Why This Matters
- Vertical Integration Strengthened
Secures GBP’s supply of linerboard + medium for >10 converting plants. - Market Signal
While many producers shutter capacity, GBP is expanding — a strong vote of confidence in future demand. - Sustainability Leadership
Project PowerPack aligns with customer expectations from companies like Amazon, Walmart, and major food brands that prioritize low emissions and responsible sourcing.
Industry Risk Without Investment
Risks for Corrugated Producers (Without Mill Investments)
- Greater exposure to linerboard price swings
- Higher unit costs from energy-inefficient assets
- Growing CO₂ and compliance pressure
- Lower competitiveness vs. modern “green” mills
- Supply disruptions hit harder when capacity is tight
Practical takeaway: modernization is no longer only about capacity — it is about cost, carbon, and resilience.
GBP’s decision to invest during a downturn is a classic counter-cyclical strategy — preparing capacity for the next upturn in demand.
Local & Economic Impact
| Impact Category | Approximate Figures |
| New Permanent Jobs | ~35 additional roles |
| Existing Mill Workforce | ~620+ employees |
| Construction Workforce (Peak) | ~1,200 contractors |
| Land for Expansion | 300 acres |
| Community Contributions | $1M+ (e.g., sports facilities) |
Conclusion
Project PowerPack is one of the largest industrial investments in Central Arkansas history. Through capacity expansion, modern sustainability technologies, and strategic foresight, Green Bay Packaging is shaping the future of corrugated production in the U.S. This project not only strengthens GBP’s competitive position but also signals a broader industry shift — toward resilient, responsible, and forward-looking manufacturing.
As construction advances toward its 2028 completion, the corrugated sector will be watching Morrilton closely — where scale, sustainability, and strategy converge to define the next chapter in packaging.
corruga.expert
