The new Unifibres facility has been constructed adjacent to Essity’s existing Prudhoe Mill, which is the company’s largest manufacturing site in the UK.
According to Essity, the investment is its largest in the UK for more than a decade and significantly expands the company’s recycled fibre processing capability.
Capacity at Prudhoe has increased to more than 105,000 tonnes per year, while Essity’s total UK recycled fibre capacity now stands at around 190,000 tonnes annually.
The 4,150 square metre facility replaces the former Unifibres complex and incorporates updated processing technology designed to handle a broader range of recovered paper grades, including lower-grade paper and board materials.
Martin Hallissey, Site Manager at Essity’s Prudhoe mill, commented: “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.”
The plant was originally supposed to open in April 2026, but was delayed due to some issues identified which the company wanted to improve before the machine is run at full capacity.
Essity to recycle fibre into tissue products
Essity said the development would help retain valuable fibre materials within the UK supply chain for longer and support more circular tissue manufacturing.
The company added that the plant is expected to improve contaminant separation, including plastics, reduce the risk of material being sent to landfill and support improved energy efficiency across operations.
The facility will supply recycled fibre for tissue products manufactured under brands including Cushelle, Velvet and Tork.
Essity also said the site would provide a platform for testing fibre innovations aimed at reducing reliance on virgin wood pulp and increasing the use of recycled and alternative raw materials in tissue production, while maintaining hygiene and quality standards.
Völker Zoller, President of 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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