Driving Measurable Energy Reduction at Atlantic’s Paper Mills

At Atlantic Packaging Products’ Whitby facility, sustainability is driven by operational excellence and advancing energy-saving solutions in sustainable paper packaging within North America’s manufacturing sector. 

Through a more than 20-year partnership with Enbridge Gas and active participation in its Industrial Energy Conservation Program, Atlantic continues to implement high-impact initiatives that improve industrial energy efficiency. 

The Whitby facility has achieved strong progress in environmental stewardship. In 2025, it reached a 30% water reuse rate and reduced water consumption per tonne of paper by up to 29% year-over-year. These improvements are supported by the use of water-dissolvable inks and dedicated treatment systems that ensure discharged water meets strict quality standards. 

Most recently, three major upgrades at the Whitby facility—the PM3 Headbox Upgrade, PM4 Wet End Upgrades, and PM4 Size Press Upgrade—have delivered measurable results in natural gas consumption and associated greenhouse gas emissions reduction. 

These projects represent one of the most impactful advancements in energy efficiency at this site in recent years. To learn more about it, we spoke with representatives from Enbridge and Atlantic teams.

A Long-Standing Partnership Driving Industrial Energy Efficiency 

Atlantic’s collaboration with Enbridge spans over two decades, resulting in numerous high-impact energy-saving solutions across facilities in Ontario. 

“Atlantic has worked with us for as long as this program has existed—over 20 years. We’ve supported major projects including the PM3 shoe press upgrade at Whitby, anaerobic digester biogas production, blowdown heat recovery, and feedwater economizers. 

These upgrades demonstrate how thoughtful equipment choices and process improvements can deliver meaningful reductions in energy use while maintaining strong production performance.”

— Kirishaa Satkunam, Energy Solutions Advisor, Enbridge 

The latest incentive reflects the combined impact of three major Whitby projects focused on industrial energy efficiency and emissions reduction. 

Project Impact at a Glance 

PM3 Headbox Upgrade 

• Annual Natural Gas Reduction: 1,274,865 m³ 
• CO₂e Reduction: 2,780 metric tonnes/year 

The upgraded headbox improves fiber distribution and enables a two-ply configuration, enhancing drainage early in the process. This reduces starch demand and lowers thermal energy requirements—supporting energy-efficient manufacturing processes. 

PM4 Wet End Upgrades 

• Annual Natural Gas Reduction: 1,163,033 m³ 
• CO₂e Reduction: 2,536 metric tonnes/year 

By increasing mechanical water removal through a high-performance shoe press and advanced headbox design, Atlantic reduced drying demand—directly contributing to natural gas reduction in manufacturing and improved industrial energy efficiency. 

PM4 Size Press Upgrade 

• Annual Natural Gas Reduction: 6,737,621 m³ 
• CO₂e Reduction: 14,691 metric tonnes/year 

The high-efficiency film sizer allows precise starch application, minimizing excess moisture and significantly lowering thermal energy requirements—advancing energy-saving solutions and greenhouse gas emissions reduction. 

As Kirishaa Satkunam, Senior Energy Solutions Advisor – Industrial Energy Conservation at Enbridge, notes “Collectively, these upgrades remove millions of cubic metres of natural gas demand annually while improving strength, smoothness, and consistency of the finished sheet.” 

Engineering Insights: Driving Sustainable Paper Packaging 

 

Q: What energy optimizations were achieved?

Suhel Bace, Energy Engineer, Atlantic Packaging Products  (Suhel): The focus across PM3 and PM4 was simple: improve sheet strength and quality while reducing energy intensity. On PM3, the new headbox improves formation and drainage at the earliest stage. On PM4, the size press ensures the appropriate amount of starch is applied. The shoe press increases mechanical water removal before the dryers. These upgrades directly support energy-efficient manufacturing processes by optimizing drainage and minimizing excess water and starch use.  

Q: Why is mechanical water removal critical?

Suhel: Since 80–90% of our natural gas use is tied to thermal drying, every litre of water removed mechanically translates directly into energy savings. 

Matthew Segat, Process Engineering Co-op, Atlantic Packaging Products (Matthew): The less water we need to evaporate, the less fuel we consume. Mechanical efficiency drives thermal efficiency. 

Q: Why prioritize natural gas reduction in manufacturing?

Suhel: There’s always a cost component — energy is a major operating expense. But beyond that, reducing direct fuel consumption is central to our Scope 1 and Scope 2 emissions targets. 

We’re a recycling-based business. Environmental stewardship isn’t separate from operations — it’s embedded in how we run our mills. Reducing natural gas use lowers emissions and strengthens long-term sustainability. 

Sara Lashari, ESG Program Manager, Atlantic Packaging Products (Sara): The incentive supports the investment, that’s where the long-term impact lies. These projects deliver recurring value—ongoing greenhouse gas emissions reduction and long-term operational savings. 

Q: How do these projects support Atlantic’s 2030 sustainability goals?

Sara: Every major capital project is evaluated through both a performance and sustainability lens. These upgrades represent measurable progress toward our 2030 targets. 

Suhel: Starting with high-efficiency, state-of-the-art equipment allows us to operate proactively rather than retrofitting later. The incentive cheque helps fund energy-saving solutions and future initiatives — but the real benefit is sustaining reductions in natural gas purchases and verified GHG reductions year after year. 

Q: What criteria did these projects meet for incentive eligibility?

Suhel: We worked closely with Enbridge from the outset. Engineering analysis and payback modelling are critical. We completed case studies prior to installation and validated results afterward by measuring moisture levels and energy consumption. The savings were not theoretical — they were verified through operational data.  Collaboration was key to achieving industrial energy efficiency. The production, energy, environmental teams, and external partners all contributed. Installing equipment is one step; optimizing it requires coordination and time. Operators played a major role in achieving performance targets quickly.  

Q: Were there any challenges to implementing these upgrades?

Suhel: Any large-scale upgrade comes with challenges. Performance claims must translate into real-world results. Data collection, commissioning, and team alignment are critical. This was a cross-functional effort — not an individual accomplishment.  Major equipment like a headbox doesn’t reach peak efficiency on day one. The production teams needed to take time to fully understand and optimize the equipment. Continuous improvement and operator engagement were essential to realizing the full energy benefit. 

Driving Sustainability Forward as One Team 

The PM3 and PM4 upgrades demonstrate how operational excellence and environmental responsibility work together to advance sustainable paper packaging. 

By improving formation, strength, and drainage, Atlantic enhanced product quality while achieving measurable natural gas reduction in manufacturing and long-term greenhouse gas emissions reduction. 

These are not one-time gains—they are embedded improvements that strengthen energy-efficient manufacturing processes for years to come. 

As the Atlantic Packaging group of companies continues progressing toward its 2030 sustainability goals, these projects highlight what’s possible when engineering, production, and sustainability teams align to deliver impactful energy-saving solutions across the paper packaging industry. 

Through innovation, partnership, and measurable results, Atlantic is building a more efficient, resilient, and sustainable future.