Background
A leading manufacturer of shop towels, disposable wipers, towel & tissue, and absorbents made with recycled fibers, faced a sudden supply chain disruption. For over a decade, other paper companies had supplied materials to the manufacturer known as DRC (double-re-crepe) base sheets. Double-re-crepe is a process known for its strength and absorbency and DRC wipers are known for their cloth-like feel. However, when these suppliers redirected production for internal use, the manufacturer needed a new partner. They turned to BiOrigin Specialty Products’ (BSP) Ladysmith, WI mill, presenting a unique opportunity to fill the gap.
Challenge
BSP-Ladysmith had not previously produced DRC base sheets, as their capabilities were limited to light dry crepe (LDC) rather than the wet crepe process used by the previous suppliers. Additionally, the required fiber composition and basis weight—50% heavier than Ladysmith’s typical production—posed significant technical challenges.
“This opportunity dropped in our lap in the middle of December 2023,” explained Mark Bittner, Mill Manager for Ladysmith. “Two weeks later, we were already making paper for them.”
Approach
Despite these challenges, the Ladysmith team—collaborating with BSP’s New Product Development team and customer’s technical team—prioritized and completed trials at an unprecedented pace. These trials explored grades ranging from 25# to 34# and ultimately proved the viability of LDC base sheets for the shop towels. Key adjustments included:
- Developing a 25.5# sheet that met the quality of the customer’s 27# wet crepe sheets, providing fiber and cost savings.
- Reducing cross-direction shrinkage compared to wet crepe sheets, enabling the customer to ship smaller rolls and minimize waste.
“The fiber is different than what we typically run,” Bittner said. “And the basis weight is 50% heavier than what we have ever successfully run before.”
Solution
The Ladysmith team’s willingness to innovate and collaborate paid off. They overcame machine limitations and pushed production boundaries, supported by leadership’s encouragement to take calculated risks.
Jenna Kenyon, #4 Paper Machine Process Area Lead, highlighted the group effort involved: “More than one-third of the Ladysmith Mill contributed, including maintenance, machine operators, quality, and leadership. The fact that we can make paper they can use is good.”
While Ladysmith currently produces bleached and blue-dyed products for the customer, plans are underway to expand to unbleached and other pigmented offerings. “We’re way outside of where we ever thought we could be on the machine setup, but we made it work,” Bittner explained.
Results
BSP’s innovative approach delivered tangible benefits:
- Cost Savings: The lighter 25.5# sheet provides fiber efficiency and reduces material costs.
- Operational Efficiency: Minimized shrinkage enables smaller roll sizes, optimizing shipping and storage.
Тhe customer values BSP’s flexibility and collaborative spirit. According to Bittner, “Other companies are unwilling to push their machines outside of their comfort zone. We’ve earned trust by stepping up to the challenge.”
Next Steps
The Ladysmith team is addressing remaining challenges, including fixing rollup issues and refining processes for sustained production. Once resolved, the partnership is expected to yield significant long-term benefits.
“There is pressure on us to move as quickly as we can,” Bittner said. “And we want to move quickly because we recognize how valuable this new business will be.”
Conclusion
BSP-Ladysmith’s swift response and innovative problem-solving have positioned the company as a reliable partner. By embracing challenges and exceeding expectations, the Ladysmith team has set a strong foundation for a fruitful and enduring partnership.
