Seventeen Forest Biomaterials graduate students recently took part in a two-day immersive visit to Smurfit Westrock facilities in West Point and Richmond, Virginia. Organized by the Forest Biomaterials Graduate Student Association (FB GSA) executive team, in close coordination with Dr. Daniel Saloni and Dr. Hasan Jameel, the visit offered students a rare opportunity to gain close exposure to the paper and packaging industry. Across two days, the group moved from large-scale mill operations to pilot-scale innovation and research facilities, gaining a clearer understanding of how academic concepts translate into industrial practice.

The visit began on Thursday, April 23, early morning at Smurfit Westrock’s West Point Mill, which was coordinated by Elijah Gore. After a detailed safety orientation by the West Point team, the students were welcomed onto the mill floor for a guided tour. The scale of the mill immediately stood out. For many students, experiencing commercial paper production in motion was one of the most memorable parts of the experience. The highlight was the state-of-the-art 3-ply paper machine, which demonstrated the precision, speed, and engineering complexity behind modern papermaking. Watching paper being formed, pressed, dried, and wound at an industrial scale made familiar technical concepts feel more tangible and relevant.

The group also had the opportunity to observe fiber generation and processing operations. These sections of the tour helped students better understand how raw fiber is prepared, refined, and managed for large-scale production. The West Point team’s sincerity in explaining the process and responding to student questions made the visit especially valuable. By the time the group finished their tour, the students were already discussing what they had seen, connecting observations from the mill floor with their coursework and research.

The second day took place at Smurfit Westrock’s Richmond Innovation & Design Center and offered a different, but equally important, perspective on the company’s work. The day began with a warm welcome and delicious doughnuts, followed by an overview of Smurfit Westrock from Fritz Paulsen, Antonio Suarez, and Ashok Ghosh. This session introduced students to the company’s scale, vision, and commitment to sustainable paper and packaging solutions. Following the mill visit, the corporate and innovation-focused perspective helped students understand how operations, research, sustainability, and market needs come together within a global packaging company.

The facility tours were a major highlight of the Richmond visit. Led by Liam Ryan, Gaytri Sharma, Jessica Christian, John DeJarnette, Adele Panek, Emma Bostic, and Cami Clickner across two rotations, students explored the pilot plant and analytical research facilities. The in-house analytical instrumentation made a strong impression, with students noting the quality and range of equipment available for paper and packaging research and development. The pilot plant was particularly engaging, featuring roll-to-roll systems, printing capabilities, and an old corrugated cardboard repulpability plant equipped with commercial refiners. These facilities demonstrated how ideas can be tested, optimized, and scaled between laboratory research and full industrial production.

After lunch, the focus shifted to the NC State graduate students, who presented their research to the Smurfit Westrock team. Their presentations covered barrier coatings, functional coatings, fiber modification strategies, and process optimization for high-barrier sustainable packaging. The exchange created a meaningful bridge between academic research and industry priorities, giving students the chance to share their work with a professional audience and receive valuable engagement from experts in the field.

The visit concluded with lunch and closing remarks from Antonio, bringing the two-day experience full circle. Students returned with new technical insights, stronger industry awareness, and a deeper appreciation of the possibilities within paper, packaging, and sustainable biomaterials.

Acknowledgements

Events like this couldn’t be possible without dedicated people working behind the scenes. The FB GSA executive team deserves significant credit for the initiative and coordination that made this visit a reality. Their efforts to create meaningful professional development opportunities for their peers reflect exactly the kind of leadership that defines the Forest Biomaterials graduate community at NC State.

Special thanks are due to Dr. Daniel Saloni and Dr. Hasan Jameel, whose guidance and support were instrumental in organizing the visit and ensuring its success. Their commitment to connecting students with industry partners remains one of the program’s defining strengths.