Essity unveils £30 million recycling facility

A Northumberland manufacturing site has undergone a multi-million-pound transformation focused on expanding sustainable production.

Health and hygiene company Essity has opened a redeveloped recycled fibre processing facility at its Prudhoe mill following an investment of more than £30 million.

The new Unifibres facility replaces older infrastructure with modern technology designed to process a wider range of recovered paper materials, including lower-grade paper and board.

Bosses say the development increases recycled fibre processing capacity at the Prudhoe site to more than 105,000 tonnes annually, bringing the company’s total UK recycled fibre capacity to around 190,000 tonnes per year.

Located beside Essity’s existing Prudhoe mill, the company’s largest manufacturing site in the UK, the 4150sq metre facility will support the production of household tissue brands including Cushelle, Velvet and Tork.

The technology will improve contaminant separation, reduce landfill waste and strengthen energy efficiency across operations.

Martin Hallissey, site manager at Essity’s Prudhoe mill, said: “The opening of this recycled fibre facility is a proud moment for everyone at Prudhoe. 

“It’s a significant investment in our site and our people, and it strengthens our ability to source recycled fibre while improving efficiency and reducing waste. 

“This facility puts Prudhoe at the forefront of sustainable tissue manufacturing in the UK.” 

Representing Essity’s largest capital project across its five UK sites in the past decade, the investment reinforces the company’s long-term commitment to manufacturing and technical development in the North East.

Future fibre innovation projects at the facility will focus on reducing reliance on virgin wood pulp while increasing the use of recycled and alternative raw materials.

The opening was marked by a visit from pupils at Prudhoe Castle First School, who brought recyclable paper from home to be transformed into toilet paper at the site.

Völker Zoller, president, consumer tissue at Essity, added: “This investment demonstrates Essity’s clear commitment to sustainability and circularity. 

“Being the UK’s largest user of recycled fibre for consumer tissue, and the leading user in Europe, brings responsibility as well as opportunity. 

“The Prudhoe facility strengthens our recycled fibre supply, supports our customers’ sustainability ambitions and reinforces our leadership in sustainable tissue production. 

“In short, we are delivering genuine sustainable solutions for our customers and ultimately a clear sustainable choice for consumers.” 

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