Sappi North America has announced the completion of Project Elevate, a USD 500 million conversion and expansion of PM2 at its Somerset Mill in Maine. This will double its production capacity and will ramp it up to full volume through 2026. This Investment expands Sappi’s leadership in high-end paperboards.
July 29, 2025
Sappi North America has started delivering commercial products after completing Project Elevate—a USD 500 million upgrade and conversion of Paper Machine No. 2 (PM2) at its Somerset Mill in Maine. Production will gradually increase to full capacity by 2026.
The investment doubles PM2’s production capacity and strengthens Sappi’s position as a leader in sustainable packaging by transforming Somerset into one of the most advanced production sites for high-performance SBS (solid bleached sulfate) paperboard.
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Talking about the development, Michael Haws, President and CEO of Sappi, said, “This is a pivotal moment for Sappi North America. With PM2, we have delivered the largest rebuild in our company’s history, doubling the machine’s capacity and positioning Somerset as a leader in sustainably manufactured paperboard. The true success of this project lies in our people. Their precision, focus, and unwavering commitment to safety enabled us to complete a complex transformation, all while keeping the mill fully operational. This investment goes beyond machinery; it’s about laying the foundation for long-term innovation, sustainable growth, and lasting impact.”
As production continues to ramp up, this strategic investment is planned to deliver 520,000 short tonnes (approximately 470,000 metric tons) of annual capacity and expands Sappi’s ability to produce a full range of high-performance SBS paperboard grades, including folding carton, food service board, and cups. .
This positions Sappi North America as a full-service SBS provider, enhancing its ability to support both domestic and global packaging customers with advanced technology that delivers superior product quality and consistency.
Kirk Ross, VP of Manufacturing added, “Product from the new machine is now commercially available, delivering the same high standards of quality and performance our customers expect, while expanding our range of applications. With increased capacity and a focus on improved service, we’re able to meet growing demand with greater speed, consistency, and responsiveness.”
Sappi North America began the PM2 conversion in 2022, following the successful rebuild of PM1 in 2018. These upgrades demonstrate Sappi’s commitment to modernizing its operations in ways that support both business growth and environmental responsibility.
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“This conversion represents a major step forward in our global packaging strategy,” said Steve Binnie, Chief Executive Officer of Sappi Limited. “It reflects our commitment to long-term growth and to broadening Sappi’s portfolio of packaging solutions our customers need.”
With the completion of construction on Project Elevate, Sappi further solidifies its leadership in high-quality paperboard and reinforces its investment in U.S. manufacturing, innovation, and the future of sustainable packaging.
