Essity Delays Opening of £30 Million Prudhoe Recycling Facility to Optimize Performance

Essity has announced a delay in the formal opening of its £30 million recycled fibre facility in Prudhoe, Northumberland, by approximately 12 weeks, as the company undertakes final performance improvements following initial start-up.

The facility, which began operations last week, is currently running and producing recycled fibre as expected. However, minor operational issues identified during the early phase have prompted the company to postpone the official opening event—originally scheduled for April 9, 2026—to ensure optimal performance before reaching full production capacity.

Gareth Lucy, Corporate Communications Director at Essity, said:

"We have successfully started up our new recycled fibre facility in Prudhoe, and it is already operational, recycling fibre for use in our paper products. As is common with projects of this scale, we have identified some initial adjustments that we want to address before operating at full capacity. We are focusing on these improvements over the coming weeks and have therefore decided to postpone the formal opening."

The Prudhoe facility represents Essity’s largest investment across its six UK sites in the past decade and marks the completion of a major modernization project. Construction began in 2023 following planning approval in late 2022.

Designed to replace a 50-year-old recycling plant, the new installation incorporates advanced paper recycling technologies, including a modern pulping system capable of processing a wider range of recovered materials. The facility is expected to expand Essity’s recycled fibre capacity to over 100,000 tonnes annually.

The upgrade also reflects a strategic shift in raw material sourcing. While office paper has traditionally been a primary feedstock, declining availability—driven by digitalization and remote working—has led Essity to increasingly utilize mixed household paper and lower-grade materials.

"This investment is critical to securing the long-term future of the Prudhoe mill. It reduces reliance on virgin pulp, enhances our ability to recycle lower-grade materials, improves energy efficiency, and supports a safer and more sustainable working environment for our employees," an Essity spokesperson added.

Once fully operational, the facility will support the production of Essity’s well-known consumer tissue brands and strengthen the company’s position in sustainable paper manufacturing.

Essity confirmed that it remains focused on ensuring a smooth ramp-up process and uninterrupted supply to customers during this period.