The Digester Calendering THE Wood chips are cooked in Processing and Screening The sheet is fed through hot soft- the digester with water and Dyes and other additives are blended nip calenders calibrated to specific The Washing Stage Bleaching Sheeter white liquor to release wood The fibers are cleaned and Somerset employs Elemental to exacting standards that achieve Surface Coating temperatures and pressures to Dryer Section Depending upon the paper fibers composed primarily Chlorine Free (ECF) bleaching, precise opacity, brightness and shade The appropriate coating is create a perfectly smooth surface. PAPERMAKING separated from the cooking The sheet is solidified Finishing order, the reels are cut of cellulose. which is considered by the depending on the specific paper. Pressing now applied to both sides chemicals by going through as it’s put through a Jumbo reels are cut into into specified sheet sizes EPA to be the best available The sheet is squeezed through of the sheet. 12 Reeling 3 2 a series of washers. 7 series of steam-heated smaller reels by employing at our Allentown, Pa., control technology. rollers to reduce the water content The sheet is now Packaging PROCESS Debark and Chip Sheet Forming drying cylinders. slitter rewinders. sheeting facility. 4 3 from 80% to 66%. wound tightly The paper is carefully The bark is removed from the The sheet begins to take form as 10 the mixture is placed on a wire and around giant reels. 14 15 packaged and prepared logs and chipped into pieces. 5 9 taken from 99% to 80% water. for shipping. 13 2 8 16 11

PCW Another look at PCW Continuous Production Cycle Sappi is a strong advocate for recycling. However, Scan this QR code to see a video Water ProductS Unlike many other mills, the coating and calendering process Coating Reclaim we do not believe that the use of recovered fiber is explaining the use of PCW and The Somerset Mill has three state-of- The Somerset Mill draws its water from the is done on-line, in a continuous process—allowing for a one size fits all solution and we promote a practice papermaking. You can also see the Part of the process of making the-art papermaking machines that Kennebec river and utilizes it throughout the mill— greater control over the process and the creation of a more of “best use” for recycled fiber. Once paper has video by visiting sappi.com/eQ. coated paper is akin to applying are capable of producing multiple from cooking pulp to the papermaking process. consistent product. State-of-the-art scanners provide been recovered, it is important to put the recovered paint to an uncoated sheet. The brands, weights and finishes. Sappi The water loops within the mill are complex, continuous feedback to the control equipment so that the coat fiber to its best use—in the right locations and Coating Reclaim process gathers continually invests in these machines designed to use both the water and the energy weight, basis weight, and moisture are within targeted the right grades based on evaluating and balancing the left over coating created to ensure consistent availability associated with it as efficiently as possible. ranges. Since the entire process is conducted on-line, the economic and environmental consequences. when a product change is made and exceptional production flexibility. About 10% of the water intake is evaporated and paper must be exceptionally strong so that it can go through Ultimately, recycled fiber should be used in products on the machines so that all the No other paper manufacturer offers leaves the mill as steam but remains in the the process at speeds up to 4,000 feet per minute without where it displaces fiber with a higher carbon coating materials are “reclaimed” such backup assurance. local ecosphere. The remaining 90% is returned breaking. Somerset’s superior stiffness and printed ink gloss footprint. Adding recycled fiber to our grades made for future use. to the Kennebec River. are a direct result of this on-line calendering process. at Somerset actually raises our carbon footprint.

6 Sustainable Forestry 4 Pulp Refinement Steam and Power 1 Somerset will source wood only Black Liquor The pulp is modified to In addition to providing electricity, the steam generated in the process from forests that are sustainably The washing process recaptures enhance its ability to bond. is used in the form of thermal energy in the pulp mill to heat the managed. the cooking chemicals in the evaporators, the washing cycle, the digester, the slaker; it is also form of weak black liquor. used in many other parts of the papermaking process. The Recovery Boiler 7 White Liquor The heat from the burning of the black The Slaker 1 White Liquor The Evaporators The white liquor has now made a complete liquor in the recovery boiler is used to raise Green Liquor Calcium oxide, also known as lime, is added to green A mix of various sodium-based Water is removed from the weak black liquor to create a higher loop as it gets pumped back into the digester the temperature of the water in the boiler, The molten smelt is quenched in liquor in the slaker, causing a chemical reaction that chemicals is used to dissolve concentration of solids that can be burned in the recovery boiler. to start the whole process over again. water to create green liquor. converts the green liquor into white liquor. the lignin from wood. 5 ultimately generating steam. 6 9 10 12

Certified Wood Tire Derived Fuel Lime Kiln RECOVERY BOILER Mill Investment Heat Exchangers All the wood at Somerset comes Stockpiles of discarded tires are an While this recovery process Scan this QR code to see a video The Somerset Mill’s carbon footprint has Heat exchangers are used demystifying the Recovery Process. from certified or controlled environmental nuisance. Tires can collect involves the constant reuse been significantly reduced thanks to a $36 throughout the mill to You can also see the video by visiting sources—ensuring the forests water, attracting mosquitoes and of inorganic chemicals and million investment in the chemical capture and reuse thermal sappi.com/eQ. are managed in a sustainable ultimately leading to problems with generates renewable energy recovery process. As a result, the capacity energy. By installing manner. The mill achieved triple mosquito-borne diseases. At Somerset, from black liquor, there is a of black liquor has been increased equipment to recapture Chain of Custody certification we have worked with a supplier that need for some fossil fuels. In and is now processed far more efficiently. heat, the mill becomes from the Forest Stewardship Because of the magnitude of the upgrade, diverts tires from landfills, converts them order to reach a temperature ® more energy efficient and Council (FSC ), Sustainable ® to chips and transports them to the that is hot enough, the lime Somerset meets requirements for Green-e ultimately uses less fuel, Forestry Initiative (SFI®) and the mill, where they are used as an alternative kiln requires either fuel oil or certification due to electrical power resulting in cost savings Programme for the Endorsement fuel source—a great example of natural gas. generated from recovery boiler steam. as well as reduced of Forest Certification (PEFC). converting a waste stream into energy. emissions.

11 THE 8 The Lime Kiln Upgrading the recovery process has been a five- The recovery of lime is also a closed loop. By heating year project culminating in the winter of 2011. the recovered lime in the kiln, calcium carbonate is Over $36 million was invested to vastly improve Smelt Collected and Diluted Chemical Recovery converted back to calcium oxide, which is then reused the efficiency of the chemical recovery process. The sodium salts form a smelt at the bottom of to create white liquor. As a result, the mill increased its capacity to use the furnace. This material is recovered so that it black liquor, a renewable energy fuel source. PROCESS can eventually be used to re-create white liquor. THE 255 State Street 800.882.4332 Somerset Boston, MA 02109 www.sappi.com/eQ Mill AA STSTOORRYY OOFF SUSTSUSTAIAINNAABBILIILITTYY

In 2010, the mill Designed for optimal web ® ® Somerset makes 2,400 More than 85% of the total energy used at Somerset reduced its annual strength and superior heft The dependable economy tons of paper a day and is derived from renewable resources. Sappi’s high oil usage by over Somerset operates three modern and stiffness, Somerset is paper that helps you stretch 800,000 tons a year use of renewable energy results in the lowest 200,000 barrels papermaking machines that engineered for the long run your budget without reported carbon footprint among domestic coated utilize Sappi’s patented online compromising quality or 85% paper suppliers. 200,000 finishing technology Somerse t Flo environmental responsibility 2,400

Facts about Sappi’s Somerset mill There are so many unique stories and statistics surrounding The largest coated the Somerset Mill. We thought we’d share some of the more # free sheet paper mill interesting highlights in order to give you a better picture of in North America why Somerset has emerged as a beacon of sustainability based on production in our industry, and one of the most admired paper and pulp 1 800,000 mills in the world. Tons

The Somerset power plant could As a result of recent Somerset produces four ® FDA approved for direct food ® Somerset achieved triple Chain of provide enough electricity for investments, the Sappi brands: Somerset®, contact and used as the glossy Custody certification from the Forest Opened new pulp mill in 1974, a city of 56,000 people per year Somerset Mill uses Opus®, Flo® and Lusterprint® outer ply for pet food and other Stewardship Council™, Sustainable with three world-class paper Green-e® certified The do-it-all paper, a one-stop consumer bags Forestry Initiative and the Programme machines installed from 1982 energy solution for an expansive range for the Endorsement of Forest to 1990 1974 56,000 Opus of high-quality printing needs Lusterprint Certification

Tucked away in the foothills of Central Maine, Sappi’s Of course, the only way to gain a real appreciation Somerset Mill has made its name as one of the largest for all of Somerset’s groundbreaking technology coated paper mills in the world. But while its size and and sustainability efforts is to illustrate the entire technological sophistication have fueled its reputation, papermaking process and get a sense of how all the mill is fast becoming recognized as a model of these initiatives play out from the moment wood sustainability. enters the mill until Opus, Somerset, Flo and Lusterprint are shipped throughout the world. Scan this QR code to see a video highlighting all Production Notes The names, symbols, logos, and all other intellectual property of the Led by a $36 million investment in a recovery boiler companies, brands, and people appearing herein are the exclusive Somerset Satin Text 80lb/118gsm upgrade, Somerset is examining every single step of the the unique attributes of the Somerset Mill. If you property of their respective owners and should not be interpreted as don’t have a QR Code Reader installed on your 4-color process, match blue and match an endorsement of or by Sappi; any legal and equitable rights in their papermaking process to find new ways to lower its orange plus overall satin aqueous intellectual property are exclusively reserved to those owners. phone, simply visit get.neoreader.com. Once the Vertical open gate into accordion fold carbon footprint. SAPPI is a trademark of Sappi Limited. SOMERSET, OPUS, FLO, app is installed, you can use your device’s camera LUSTERPRINT and the eQ logo are registered trademarks of Sappi to scan the code and watch the video. You can also Fine Paper North America. see the video by visiting sappi.com/eQ. © 2011 Sappi Fine Paper North America. All rights reserved.

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