NC0000272_Canton Mill DENR Presentation_20110801

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CantonIF
August 2011
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•History
•Our business
•Importance to WNC and NC
•Sustainability of site and jobs
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•Overview of permits
•Mill overview and tour
No.4 Power Boiler and Town of Canton,NC
PackagingEvergreen • in 2007
2 mills, 16 converting plants, plus equipment company
Combined the assets of IP Beverage Packaging Division and Blue Ridge
Paper Products/DairyPak (former Champion DairyPak Division)
— Largest gable top liquid carton manufacturer in North America and second
largest in the world
— Provide complete fiber-based packaging solutions to our customers
including package systems,printing and filling equipment
— Have important market positions and commercial trademarks
in uncoated freesheet paper and coated groundwood paper
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DENR Visit to Canton Mill 17 Aug 2011 1

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CarolinaEvergreen Packaging Presence in
North
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CANTON MILL
WAYNESVILLE PLANT
RALEIGH FACILITY
Over 1400 Employees in North Carolina
HistoryCanton Mill Brief
• Established in 1908 to produce pulp for the Champion paper
mill in Hamilton, Ohio
- site selected for proximity to spruce,fir and chestnut trees in WNC mountains,
good water supply and access to railroad
- Discovered that the people of WNC were the greatest resource
Come for the trees, stayed for the people
• Ownership
- 190R to 1999-Champion
- 1999 to 2007-Blue Ridge Paper Products(ESOP)
- Now part of Evergreen Packaging Group
- North Carolina operations under Evergreen Packaging include
Canton Mill,Waynesville Plant and Raleigh Converting Facility
• Many changes over 100 year history of mill site •
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DENR Visit to Canton Mill 17 Aug 2011
2

Waynesville Brief History
• Waynesville Extrusion Coating Plant
— Lines 1&2-1960s
— Line 3—1988 upgraded in 1998
— Canton Mill and Waynesville plus the converting plants were the
"DairyPak Division"of Champion International
Canton Products
Products
• Bleached Kraft pulp
• Paper and paperboard
• Tall oil and turpentine
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DENR Visit to Canton Mill 17 Aug 2011 3

r-nton — Waynes - Product
Overview
Fiber-Based Packaging
Converting Plants
Waynesville ss% -.- t00% End Markets
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91% •Othera•ckffaod • Dry Goads
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P pe oc ,c Bleached End Market
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Macl're Board 9% r .'.5'g pecks oine Segment-2010
Pslpmlll — Tons sold 310,000
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PI mul End Market Equipment Company
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Oflaet ginlg Doper eteliquidaging solutions
Uncoated Freesheet Paper Pacersecment-2O10: 1
•Tons sold 290,000
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Products • ' from Evergreen Packaging
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DENR Visit to Canton Mill 17 Aug 2011 4

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Why fiber-based • best
packaging choice?
►cartons are recyclable!
+Made primarily from renewable materials - trees
�►Over half the energy used in our mills comes from
renewable energy sources
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DENR Visit to Canton Mill 17 Aug 2011 5

Carton Council - http://www.recyclecartons.com
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EnvironmentalCanton Mill
• Third party* forest product certifications:
— Sustainable Forestry Initiative° (SFI) Fiber Sourcing
— Forest Stewardship Council (FSC) Chain of Custody
Certified Chain bl Custody
LO Promoting Sustainable Forestry
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DENR Visit to Canton Mill 17 Aug 2011 6

Canton Mill Regional • • Impact
• Our jobs and contribution to regional economy are
important
— Mill is largest private manufacturing employer remaining in
Western INC
• 1200 employees in Haywood Co(Canton&Waynesville)
• Average hourly wage of$19 plus benefits
• Total payroll in Haywood Co of$90 million per year
• Payroll multiplier benefit to regional economy of 3 to 9 times
— Annual operating expenditure(wages,materials,energy,
transportation and services) in excess of$500 million centered in
Western INC
• Of this economic activity more than$50 million per year of
materials and services are sourced from Tennessee
— Annual local property taxes&fees=$1.5 million
— Annual Title V Air Permit fee=$305,000
Canton
• May 2011 Cold Mill & Extended Outage
— Largest group of outages and investment in Canton Mill since the Canton
Modernization Project in 1992:
• $22.9 MM for 31 capital projects completed
• $43 MM maintenance expense to complete 320 cold mill jobs
• $5.5 MM maintenance expense to complete other outage jobs
— Work included maintenance re-tubing of the No.11 Recovery Furnace to
extend life of this key chemical recovery biomass energy unit
— $500,000 direct economic benefit to Haywood County and WNC during 2Q
2011 from influx of 1500 contractors for outage work
— Demonstration of Evergreen Packaging commitment to site and to North
Carolina presence.
— NC DAQ helped this happen by completing NSPS applicability
determinations for the recovery furnace work in 2010
— Similar work is planned in 2013 for the No. 10 Recovery Furnace
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DENR Visit to Canton Mill 17 Aug 2011 7

Canton Mill — Environmental
Stewardship
• Protecting the Pigeon River is important
— More than$300 million spent to protect the river since 1990
— Biological health of river is good and designated uses are supported
— Wastewater from mill including color is among the best of pulp and paper
mills in the world
• Improving air quality and reducing fossil carbon emissions
are important
— More than$19 million spent since 2000 on new air emission controls
— Mill meets applicable standards and is actively planning to meet expected
future requirements for Boiler MALT and Regional Haze
— More than 40 percent of the mill's total energy input comes from renewable
sources(biomass)
— Mill uses combined heat and power,the most efficient way to make energy
from fossil and biomass fuels
— In 2011,mill is completing the Pinch Projects which will improve
thermal efficiency by additional 3 percent
Canton • the Pigeon
• Recovery of the Pigeon
River is a Clean Water Act
success story
— Mill is committed to
continued improvement as
technology allows
— NC DWQ support defending the
May 2010 NPDES permit
contested cases is important to
business confidence for Pigeon River Below Clyde
sustaining capital investment in
the Canton Mill
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DENR Visit to Canton Mill 17 Aug 2011 8

Canton Mill • thePigeon River
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Annual Avenge Effluent Color Greater than 90 percent
Blue Ridge Paper Canton Mill,1988 thou 2010
color reduction since 1988
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3w +n'W Greater than 40 percent
s 2gg reduction since 1997
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F n 1.n.n-•.0 2010 performance at
36,000#/day effluent color
is among best of mills in
Annual Average Effluent Color world
Blue Mae Paper Canlon Mot 1.0]One 2010
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a80 - - - - - - - - - - - - - - - - -
e an ae_ _ in 2010 with same
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3g - - 100,000 Wday of effluent
2g color
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Biological assessments in 2000&2005 found
a diverse and healthy aquatic community in
the Pigeon River below the Canton Mill
The next biological assessment under the NPDES Photos of univen n fTer r ress ewildlife
egos
Permit is scheduled for summer of 2012 biologinl assessment work
DENR Visit to Canton Mill 17 Aug 2011 9

SupportCanton Mill
Restoration Project
Non-Game Species Re-introduction Project
for Pigeon River, managed by University of Tennessee
• Canton Mill personnel actively promoted concept and brought
key parties together in 2000 & 2001
— Non-game fish species historically present in Pigeon River did not return
with improved water quality due to geographic barriers and other factors
— Project focus is science-based targeted re-introduction and monitoring
of these non-game fish
— Re-introductions began in TN in 2001 and in NC in 2004
— 15 species and more than 26,000 individuals have been re-introduced
— Established populations of 9 re-introduced fish species are present
— Project is internationally recognized and has produced new science
• Participate in TN and NC steering committees
• Leverage financial and technical support with others
Pigeon River Restoration Project
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DENR Visit to Canton Mill 17 Aug 2011 10

Canton Mill — NC DENR Permits
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• Canton Mill permits
— Wastewater permit—3 outfalls(2 internal) 6 primary permits, 1
— Stormwater permit—26 outfalls license,3 registrations
— Title V air permit-82 regulated sources, and more than 200
58 in-significant activities pages of permit
conditions to remember
— Landfill operating permit and track
— RCRA—Small Quantity Generator(SQG)
— Radioactive source license, 32 sealed sources
— X-ray source registration
Primary activity of 40 salaried and
• Waynesville Plant permits hourly employees is
permit compliance.
— Minor source air permit-13 sources All mill employees have
— Non-contact cooling water permit—1 outfall c,mplianu as part of their job.
— Stormwater No-exposure Certification
— RCRA ID-Conditionally Exempt SQG :
Canton
Overview
• Permit writer—DWQ Central Office-Sergei Chernikov in Permits Section
• Permit oversight—ARO Regional Office-Roger Edwards,DWQ Regional
Supervisor; Keith Haynes and Jeff Menzel,DWQ Field Inspectors
• Other oversight—DWQ Central Office Environmental Science Section—Toxicity
Testing and 316a Study
Self-Monitoring&Reporting #of Parameters&Sample Annual#of
Points Records
Daily samples and flow 11.parameters,outfall 001 4015
Weekly,monthly,annual samples 24 parameters,outfalls 001,002&003 400
River monitoring—daily&weekly 6 parameters,7 river run sites 11,570
TOTAL 15,985
• Other requirements include:
— Wastewater effluent toxicity testing-quarterly
— Dioxin testing—annual, Waterville lake fish tissue in 2011,2013&2014
— Cluster Rule BMP Program
— Special conditions for effluent color
— Special conditions for temperature including 316a Study
— Laboratory certification, one year special turbidity monitoring p-
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DENR Visit to Canton Mill 17 Aug 2011 11

Air Overview
• Permit writer—DAQ Central Office-Don van der Vaart's staff in Permits Section
• Permit oversight—ARO Regional Office-Paul Muller,DAQ Regional Supervisor;
Brendan Davey and Mike Parkin,DAQ Field Inspectors
• Other oversight—DAQ Central Office, Stationary Source Compliance Branch-Alan
Drake&James Hammond(CEMs/COMB reports,stack test protocols&reports)
Self Monitoring& #of Parameters& Annual#of Records
Reporting Inspection Points i
CEMs(NOz,TRS)ICOMs 24 parameters,9 sources 154,600 / 615,960
Parameter monitoring 95 parameters,15 sources 907,400
LVHC monitoring 20 points 700,800
VE"normalcy"observations 30 sources 1.150
LDAR inspections 692 points 8300
TOTAL 2,388,210
• Other requirements include:
— Fuel analysis/certification records,production&downtime records
— Annual compliance certification&semi-annual summary,of monitoring reports
— Annual emissions inventory,2&5 year stack testing �l�rpr�
— 1&M records,calibration records,RMP program,ODC program i
DENR Visit to Canton Mill 17 Aug 2011 12

Cocke County, TN
Year Total Rafters County Fee
Pigeon River Rafting Industry 1995 21,154 $34,674
1995-2011 1996 49,271 $79 610
y 1997 43,532 $69,484
> 250,000 _ -1998 52,245 $84,§50
1999 59,646 _ $97,080--
C
O - - -- 2000 73,536 $120,804
a1 200,000 - 2001 73,724 $121,636
a 2002 101,470 $168,840
y 2003 104,241 $172,744
r 150,000 2004 118,486 $196,608
C 2005 129,428 $215,974
O 2006 149,571 $250,224
i 2007 150,203 $252,380
100,000 - - - --- - - - _ 2008 139,970 $232,768
R 2009- 176,575 $291,962
.2010 196,513 $322,858
50,000 2011 204,553 $338,120
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Cocke County,TN
Pigeon River R19995-20i1ou9ry Revenue Thriving Rafting Industry on Pigeon
$400000 River in Cocke County, Tennessee
o,$350,000 - -
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w $300,000
m
$z5°.°°°
w Total Rafters 1995 - 2011 = 1,844,118
� $zoo 000 - - -
Total Permit Fees 1995 - 2011 = $3,050,716
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$100,000 's
$50000 - Source of information
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�5, ,�, ^ �9�8D ry8���ti ry�9 Aa ry�y ry o ry�1 ry80 ry�9 ry��0 i,, Janice A. Butler, Cocke County Clerk

From Forest to Paper
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7�Ca�nton Fully integrated bleached Kraft Pulp mill
r in the Blue Ridge Mountains of Western NC
in downtown Canton
rdwood fiber lines
ecovery Furnaces
•5 Power Boilers
•3 Paper Machines—800 ton per day
•1 Paper Board Machine—1000 ton per day
Waynesville Plant
• 250,000 scl ft paper board extrusion
coating plant
Canton Mill 3 extrusion lines—900 ton per day
• R&D package testing laboratory
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Canton Mill — Unique Features
• Bleach Filtrate Recycling(BFRTM)—only Kraft pulp and paper mill in the
world with this process
— Pollution prevention technology for containing Kraft pulp color within the process and
reducing wastewater load to treatment
• Elemental chlorine free(ECF)bleaching with 01)100TMt
— Current"state of art"minimum environmental impact technology for bleached Kraft
pulp production
• Activated sludge wastewater treatment,foul condensate steam
stripping
— Many pulp and paper mills use lagoons and the clean condensates alternative
• Wastewater treatment performance including color is among best of
Kraft pulp mills in the world
— Extensive sump systems,real time sewer process monitoring,and BMP focus on
prevention of effluent color
• Lined process waste landfill with leachate collection
— Many pulp and paper mills and electric power plants use unlined
lagoons for disposal of sludge,ash and other process waste material evergreen CV
Mill Tour Materials - August 2011 2

Canton Mill — Basic Process Flow
Pu1D
CHIPS Production LIME
1 KILNS
SCREENING CaOH 1 I Caco,
1 While Liquor
DIGESTERS CAUSTICIZING
1 Green Liquor
FIBERLINES Black Liquor
Washing EVAPORATORS — RECOVERY
FURNACES
Bleaching
c
PAPER MACHINES Paper Chemical
Production Recovery Cie
Canton • Description 1 of
• The Canton Mill is a fully-integrated Kraft pulp and paper mill with one exception-
due to space constraints the mill does not have a wood yard. The mill purchases
hardwood and softwood(pine)chips from suppliers in Western North Carolina,
Upstate South Carolina and Eastern Tennessee. The wood chips are shipped to
Canton by truck and by rail. The mill receives about 5600 short tons of wood chips
per day.
• Primary products of the mill are FDA food-grade paperboard and uncoated free-
sheet paper. Rolls of paperboard from the mill are moved by truck from Canton to
the Waynesville Plant where the rolls are extrusion coated with polyethylene and
other plastics. The extrusion coated paperboard is then shipped to converting
facilities owned by Evergreen and by other companies where the board is made
into fiber-based liquid packaging including gable top cartons,drink cups and
ovenable trays. Rolls of uncoated free-sheet paper are shipped to a variety of
customers around the world for conversion into envelopes,printing papers and
other consumer and commercial products including drywall tape,freezer wrap
and billboard paper.
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Mill Tour Materials - August 2011 3

CantonMill Process Description 2 of
• The art of papermaking is the furnish,or recipe,for making fine paper and
paperboard from a blend of hardwood and softwood cellulose pulp fiber.
Hardwood pulp fibers are short and give paper properties of opacity and
printability. Pine fibers are long and give paper tensile strength. Sizing such as
starch and other additives are used to give paper and paperboard surface
properties and wet strength required for different customer uses.
• The Canton Mill has four(4)paper machines with a nominal production capacity
up to 1800 short tons per day. Three of the paper machines—Nos.11, 12 and 20
—produce uncoated free-sheet paper. The No.19 paper machine produces FDA
food-grade paperboard.
• Parts of the Canton Mill are old,but the process is fully modern with automation
and distributed controls.
CantonPhoto Tour
Primary Input is
Wood Chips LL
5600 tons per day
Chip Piles on western end
of Canton Mill property.
Hardwood and pine wood
chips are delivered by truck
and by rail from suppliers in
Western North Carolina,
Upstate South Carolina
and Eastern Tennessee.
4
Mill Tour Materials - August 2011

Canton Mill Photo Tour
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No. 11 & 12 PM
No. 20 PM
Canton Mill Photo Tour
No 19 Paper Board Machine
y p.
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- Depoly Plant to recover
extrusion coated broke
Mill Tour Materials - August 2011 5

Canton Mill ProcessDescription 3 of
• The Canton Mill manufactures bleached Kraft hardwood and softwood slush pulp
to supply the paper machines. The mill's nominal pulp manufacturing capacity is
1420 short tons per day. The mill also purchases paper broke and dry furnish pulp
fiber as required to supply the paper machines. The mill purchases some post-
consumer recycled paper fiber to make paper grades containing recycled fiber
content as requested by customers.
• In the Kraft pulping process,wood chips are screened and then loaded into large
batch digesters where the chips are cooked with pulping chemicals call white
liquor. The digesters are large pressure cookers heated by both direct and
indirect steam. The cooking process is necessary to dissolve lignin in the wood to
free cellulose pulp fibers which are used to make paper. Lignin is nature's glue
that binds cellulose fibers together to make wood.
anton
Process • • of
• After cooking with white liquor in the digesters,the cellulose fibers freed from the
wood are washed and then bleached in fiberlines to make bleached Kraft pulp.
The Canton Mill uses elemental chlorine free,or ECF bleaching. The specific
bleaching chemical is chlorine dioxide which is manufactured on site. Bleached
Kraft pulp is a high quality virgin cellulose fiber necessary for making fine papers
and food-grade paperboard.
• In the pulp washing process,the spent pulping chemicals called black liquor are
collected and concentrated in multi-stage evaporators. Black liquor is a mixture of
lignin dissolved from wood and spent chemicals from wood digestion. The black
liquor,which is mostly lignin or dissolved wood,is burned in recovery furnaces to
recover pulping chemicals and to make energy for the pulping process. Black
liquor is a biomass fuel with a high energy content.
6
Mill Tour Materials - August 2011

Canton • cess Description 5 of
JA
• The heart of the Kraft pulping process is chemical recovery. Pulping chemicals in
the black liquor accumulate as molten smelt in the bottom of the recovery
furnace. The smelt is withdrawn from the furnace and reacted with steam and
water to make green liquor. The green liquor is then slaked with lime to re-
manufacture white liquor that is used to digest wood. The recovery furnaces and
associated lime kilns and slakers allow the Canton Mill to continuously regenerate
and recycle its Kraft pulping chemicals. The recovery furnaces make the Kraft
process efficient and economical. The furnaces generate steam as a by-product
that provides more than 40 percent of the total energy input to the Canton Mill.
• The process of cooking wood to make cellulose pulp makes two by-product
chemicals—tall oil and turpentine. The Canton Mill sells tall oil and turpentine as
feed stock chemicals to other companies.
Canton Mill Photo Tour
i
Pulp manufacturing -
Pine Fiberline and
Recovery Furnaces
Mill Tour Materials - August 2011 7

Canton •cess Description 6 of
• The Canton Mill includes a large utility complex to support mill operations. These
utilities include a raw water plant,a steam plant with electrical power generation
and wastewater treatment. In addition to black liquor solids,the mill burns coal,
wood and fuel oil to make steam and electricity. The mill uses combined heat and
power which is a very efficient process for extracting maximum energy value from
fuel. The mill generates electric power in turbines powered by steam from the
recovery furnaces and power boilers. The steam extracted from turbines is then
reused for process heat. Overall thermal efficiency of 65 to 70 percent is
obtained. The typical electric utility power plant without combined heat and
power achieves only 35 to 40 percent thermal efficiency.
• The mill self-generates 80 percent of its total power needs and purchases
additional electrical power from Progress Energy.
Canton Mill Photo Tour
Site utilities include
raw water treatment
to make process
water to operate the
mill
I
t l� Hill Filter Plant
Low Head Dam
Impoundment for
Riverintake
Mill Tour Materials - August 2011 8

Canton Mill Photo Tour
Steam Plant Utilities
include 5 power boilers
and two recovery furnaces /{
Fuels include wood, coal,
black liquor solids and oil
Canton Mill Photo Tour
Power Boilers,
Generator Room
and Emission
Monitoring
MV
Generator room
and boiler operators
Mill Tour Materials - August 2011 9

Canton Mill Photo Tour
Wastewater Treatment
Plant
Effluent quality is among the
best of Kraft pulp and paper
mills in the world
Color performance is
excellent— Canton Mill is
recognized as an industry
leader
Canton Mill Photo Tour
Landfill No.6
Evergreen Landfill and Solar
Farm
The Evergreen Landfill No.6 is a
state of art process waste landfill
with liner and leachate collection.
The landfill is home to the
Evergreen Solar Farm—a
demonstration project built in
partnership with Progress Energy
and FLS Energy. The solar farm is
the first of its kind to be built on a
closed landfill cell and one of the
largest PV installations in NC at
0.55 Mw.
Evergreen Solar Farm on Closed Cell at Landfill No.6
Mill Tour Materials - August 2011 10

• • • •
F
• Why can't the mill use 100 percent recycled fiber to make paper and save trees?
Paper and cellulose fiber recycling is an important industry that the Canton Mill
supports by producing virgin fiber which starts the paper recycling process. A
cellulose fiber breaks down when recycled and can only be recycled a few times
before it falls apart. Virgin pulp mills are necessary to have paper recycling. The
high quality papers and paperboard manufactured at the Canton Mill require virgin
bleached Kraft pulp. The mill does manufacture some paper grades with post-
consumer recycled fiber content. The recycled fiber is purchased from paper
recycling mills.
• Why can't the mill use total chlorine free,or TCF bleaching? For several technical
reasons the fiber-based packaging products and paper products made by Evergreen
and our customers require the ECF bleaching process. The TCF process destroys
cellulose fiber strength and is detrimental to paper quality.
Canton • • Questions
• Are Canton Mill wood supply practices sustainable? Yes,Canton Millwood
sourcing abides by sustainable forestry practices and has done so for many years.
We are third-party certified to the Sustainable Forestry Initiative or SFI standards
for responsible wood source procurement and harvesting. We actively work with
our loggers and chip supply partners to help them maintain SFI standards and
certification. We are also third-party certified for chain-of-custody wood source
product labeling. The mill is an important part of the forest products industry and
provides a regional outlet for wood residuals,particularly hardwood,that would
otherwise go to waste when trees are harvested for more valuable purposes such
as telephone poles,lumber,plywood and veneer.
Sustainable Solutions
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Mill Tour Materials - August 2011 11