Reducing Mill Waste at Mercer Peace River: What We’ve Learned About Closing Gaps in Efficiency

Reducing Mill Waste at Mercer Peace River: What We’ve Learned About Closing Gaps in Efficiency

At Mercer Peace River, reducing mill waste is about more than compliance or cost; it’s about strengthening operational excellence and fulfilling our responsibility to use every fibre wisely. As a kraft pulp mill operating in a resource-intensive sector, we’ve made it a priority to understand where waste occurs in our processes and how we can systematically reduce it.

Understanding Waste Through a New Lens

Our work begins with data. Through deeper tracking and cross-departmental coordination, we’ve identified key areas where fibre loss, energy inefficiencies, or equipment performance gaps were impacting overall yield. From the woodroom to the recovery boiler, we’ve focused on increasing process visibility.

“We used to look at byproducts of production as waste. Now we see it as a missed opportunity,” says Stephan Szabo, Director of Continuous Improvement at Mercer Peace River. “By engaging our team members and giving them the autonomy to explore opportunities, we’re finding ways to reduce loss and improve recovery.”

Fibre Efficiency in Focus

Fibre utilization is one of our most meaningful areas of progress. We’ve increased pulp yield and reduced material losses by improving chip quality, optimizing digester conditions, and reducing variability in washing and screening. These are measurable gains that support both environmental performance and cost efficiency.

In the woodroom, targeted adjustments to equipment settings and material handling have reduced oversize and fines, leading to more consistent chip sizing and better throughput and in less fibre left behind.

From Residuals to Resources

We’ve also advanced how we use residuals, transforming bark and biomass into energy and exploring circular opportunities beyond the mill. Our goal is to treat byproducts not as waste streams, but as resources with value. This thinking aligns with Mercer’s broader vision of bioproduct innovation and resource efficiency.

As Stephan Szabo emphasized, “By maximizing the utilization of biomass for things like energy generation, we’re reducing fossil fuel reliance, further lowering  our carbon footprint.”

Lessons on the Path to Zero Waste

The path to zero waste isn’t linear, but what we’ve learned is that improvement is always possible when teams are empowered, data is shared, and accountability is embedded in daily operations.

Looking ahead, we’re exploring advanced analytics and AI tools to help predict and prevent waste events before they occur, continuing our push toward smarter, cleaner production.

At Mercer Peace River, waste reduction is not a project with an endpoint. It’s a way of working, grounded in continuous improvement, sustainability, and a commitment to maximizing the value of every tree we touch.