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DS Smith Opens New Manufacturing Plant

DS Smith announced the opening of its state-of-the-art 550,000 sq-ft manufacturing facility in Lebanon, IN.

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The opening of the corrugated plant heralds the company’s latest technologyβ€”keeping pace with increasing demands by consumers and retailers for fully recyclable boxes and β€œfit-to-product” packaging that reduces costs, waste, and β€œpacking air” of irregularly shaped items. The facility can produce about 30,000 boxes/hr and 2 billion sq-ft of recyclable packaging a year. An underground scrap conveyer system will drastically reduce dust and noise typically found at conventional box plants.

DS Smith embraces sustainable strategies and views this plant as a job-creating economic catalyst for central Indiana.

β€œOur new facility in Indiana is unique to the U.S. market,” said Miles Roberts, Group CEO of DS Smith. β€œWith our innovative packaging design and focus on sustainable materials, we can support our customers’ needs in a changing world, no matter how sophisticated their requirements. We look forward to serving many of the global brands we work with in Europe, as well as a range of new customers, with their U.S.-based packaging.”

Made with the lightest possible materials, a widespread practice by DS Smith in Europe, the Indiana-produced boxes will utilize 30% to 40% less fiber than what is traditionally used in the U.S. The lightweight material is a key differentiator of the products DS Smith will manufacture at the new facility. These next-generation boxes will enable brands to meet growing consumer calls for more sustainable packaging and a reduction of shipping costs across the U.S.

The facility was designed to model three cutting-edge DS Smith locations in Europe that are highly automated, customer-centric plants which can accept and process high-volume orders with short lead timesβ€”many with same-day turnaround.

"Our new box plant stands apart from the rest in the industry and is equipped with state-of-the-art equipment and machinery that relies on fully automated operations,” said Mark Ushpol, managing director of packaging for DS Smith in North America. β€œOur talent and teams are free to focus on working directly with customers designing custom packaging that reduces system waste, drives sustainability and provides immediate value to the supply chain.”

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