Funded project – Establishing Victoria’s first sustainable edge board manufacturing line

Background

The Broadford Mill is a regional manufacturing business in Victoria, operating since 1890. It is using recycled paper from its own mill to make a new product: angle board (also known as edge board and corner board), a multi-ply paper angle used to protect pallet and carton edges.

Through this project The Broadford Mill has implemented an angle board production line. The mill is now the only angle board manufacturer in Victoria and Australia with complete on-site processing capabilities. Angle board products from The Broadford Mill are widely used across Victoria and the rest of the country.

To meet the increased demand, The Broadford Mill has invested in expanding its operations by acquiring a third rewinder machine. This machine processes large paper reels and slits them down to the required size. For instance, The Broadford Mill’s angle board machine uses ribbons ranging from 60 millimetres to 230 millimetres to manufacture angle boards.

The Broadford Mill will also build a new reel store and extend existing angle board sheds to enhance the mill’s production capacity.

Objectives

The objectives of the project were to:

• Deliver a recycling production plant to increase Victoria’s capacity to recycle paper and cardboard waste.
• Support Victorian businesses to increase recycling and reduce costs associated with disposing of and recycling paper and cardboard waste.
• Create new jobs in regional Victoria.
• Introduce a locally made and recyclable circular-economy product: edge board, manufactured from pre-consumer paper and cardboard waste.
• Reduce imports of plastic edge board.
• Reduce waste to landfills.

Process

• Team establishment and preparation: The project’s first step was forming the project team and preparing for the upcoming tasks and activities.
• Power supply upgrades and building modifications: Necessary upgrades were made to the power supply infrastructure, and modifications were done to the existing buildings to accommodate the new infrastructure.
• Procuring machinery: The machinery needed for the project is from France. Coordinating with the supplier took a few months to ensure delivery aligned with the project timeline.
• Testing and functionality checks: Once the equipment was delivered thorough testing and functionality checks were conducted to ensure the machine operated as intended and to identify and address any potential production or processing issues.
• Installation and commissioning: Once the machinery was deemed functional, it was installed on site and fully commissioned. This involved comprehensive testing to ensure compliance with standards and regulations.
• Training and skill development: During the commissioning phase, training sessions on the safe and efficient operation of the equipment were held for staff. These sessions were an opportunity for staff to ask questions and be guided by the installer facilitating their learning and skill development.

Challenges

There were some issues with what the machine could achieve, which limited the products that could go to market. The team had to invest more to address the gaps in production. The problem was limited functionality: the machine could not effectively handle "U channel" or "flat" products and struggles with machining the 50-millimetre and 100-millimetre angle boards. Contacting and working with the overseas supplier was also challenging. Incorrect information from the supplier meant more people than anticipated were needed to operate the machine.

Adhesive issues

There were limitations with the adhesives. The few angle board and core making machines in Australia using the same adhesive could only operate at 40 metres per minute while the machine operates at 80 metres per minute. Adhesives available in Australia were rated for lower speeds and would not effectively bond at higher speeds.

To rectify the adhesive issue The Broadford Mill worked closely with the local adhesive’s supplier. The Broadford Mill collaborated with the owner and an industrial chemist to develop a specialised formulation that addressed the adhesive limitations. The formulation was highly effective, allowing the machine to operate at the intended speed of 80 meters per minute.

Lack of experience

Although the mill’s team has extensive experience making solid fibre boards and paper converting, producing angle boards was a new endeavour. Producing angle boards presented a significant learning curve that the team was not adequately prepared for.

Outcomes and impact

• The team has gained valuable knowledge and insights, and is now better equipped to handle similar projects in the future.
• The locally made edge board product has been well-received by the market, with positive feedback on its quality.
• The project aligns with The Broadford Mill's vision of producing sustainable, recycled, and recyclable products in a cost-effective manner.
• The Broadford Mill's use of downgrade damaged stock and waste ensures that waste materials are diverted from landfills.
• The project has exceeded its targets, thanks to thorough planning throughout its implementation.
• Presentations have been conducted to showcase the viability and success of the new infrastructure to industry stakeholders.

What’s next?

• The Broadford Mill’s team is in the process of commercialising. There has been a strong uptake of the product and steady growth.
• The mill is installing another rewinder machine to meet the growing demand for the angle boards.
• The angle board shed on site may be extended to enhance production capacity, and the mill is exploring plans to build a new reel store, a warehouse for storing paper reels and finished products.
• The Broadford Mill is developing a marketing strategy and other investment opportunities and potential expansion.
• There is the possibility to buy a new specialised machine for producing small angle board pieces.

From the grantee:

More information

Visit The Broadford Mill