WestRock, a corrugated packaging company based in the US, will open a new corrugated box manufacturing facility in Pleasant Prairie, Wisconsin, to address the increasing demand from customers within the Great Lakes region.
Announced in January 2024, the project is being developed with an estimated investment of $140m. It will enhance WestRock’s production capabilities and improve its cost profile in this key geographical area.
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WestRock entered into a build-to-suit lease agreement with Dermody Properties, a national real estate investment, development and management company specialising in logistics real estate, to build their facility at LogistiCenter℠, a logistics and distribution hub at Pleasant Prairie.
The ground-breaking ceremony for the project was held in June 2024. The facility is anticipated to be completed in 2025.
WestRock then plans to close its existing plant in North Chicago and transition operations to the new facility.
Location
WestRock’s corrugated box facility will be located in the LogistiCenter, a three-building logistics and distribution hub with a total building space of 2.38 million ft² (221,551m²). It is the only rail-served, build-to-suit logistics park in Wisconsin. It is part of a series of industrial developments by Dermody Properties.
The strategically located logistics park offers immediate access to a major interstate highway I-94 via a four-way interchange and boasts dual rail service, courtesy of Union Pacific and the Canadian Pacific Railway.
Pleasant Prairie has become a growth hub due to its business-friendly environment, available labour force and high quality of life, making it an attractive location for companies looking to access the Midwest market.
WestRock corrugated box facility details
WestRock’s corrugated box plant will occupy more than 580,000ft² within LogistiCenter. It will be developed into a regional corrugated operations hub in the Great Lakes region with advanced automation and enhanced capabilities to improve product quality and customer satisfaction.
The facility’s design will focus on reducing production waste and expenses, thus improving WestRock’s overall manufacturing cost profile. It will also prioritise sustainability by utilising less energy and incorporating innovative technologies.
With an emphasis on digital capabilities, the facility will provide real-time data to facilitate better decision-making and reduce unplanned downtime. It will serve a variety of end markets in the Great Lakes region, including the retail, distribution, processed food, industrial and protein sectors.
WestRock product portfolio
The product portfolio of WestRock encompasses packaging, merchandising displays, packaging automation and paper solutions.
The company’s merchandising display solutions are designed to enhance brand engagement and drive sales, leveraging insights into retailer expertise and consumer behaviour.
The packaging solutions offered by the company include innovative products such as the Meta® Pop-n-Shop® container, the EnduraGrip® paperboard clip for bundling, the Cluster-Clip® fibre-based multi-pack solution for bundling and the EverGrow® collection of recyclable packaging solutions.
The packaging automation solutions include the Cluster-Pak® eMerge™ Combo, Robotic Palletizer, Wrap 8 Case Former, Meta® BornDigital™ and BoxSizer®, which streamline packaging processes and improve efficiency.
WestRock also produces a variety of paper products, including paperboard, containerboard and kraft paper. Notable products in this category include PrintKote®, TruServ®, Tango®, EnduraLiner™, Bag and Sack Paper, Multiwall, unbleached kraft pulp (UKP), southern bleached softwood kraft (SBSK) and LiquiTech® Aseptic.
Marketing commentary on WestRock
Headquartered in Atlanta, Georgia, US, WestRock merged with Smurfit Kappa in July 2024, forming Smurfit Westrock. The entity has established itself as a prominent player in sustainable paper and packaging, with operations in 40 countries, more than 500 production sites, and 63 paper and containerboard mills. It has a workforce exceeding 100,000.
Smurfit Westrock is dedicated to transforming the lifecycle of paper, from production to reuse, and is actively working towards a future centred around fibre-based materials.
Its offerings also encompass pulp products and retail displays. The company caters to a diverse range of industries, from beauty and personal care to healthcare and tobacco.
The company places a strong emphasis on sustainability and community well-being, with a focus on fostering partnerships and collaboration to enhance its operations.
