E-Newsletter - A Publication of Interstate Resources

Tuesday, October 4, 2016

Interstate Container Helps Growers Shift to Greencoat® Recyclable, Coated, Wax-Free Boxes at PMA Fresh Summit 2016

Interstate Resources News homepage: http://news.interstateresources.com

Interstate Container will work Hand in Hand with growers to help transition from wax to Greencoat® boxes at Booth #3285 during PMA Fresh Summit 2016 from October 15 – 16 at the Orange County Convention Center in Orlando, FL.

October 4, 2016, Columbia, South Carolina – Interstate Container helps growers and packers shift away from unrecyclable wax boxes in response to the growing demand from foodservice distributors, supermarket, and restaurant chains to reduce carbon footprint. During 2016 PMA Fresh Summit Convention & Expo, Interstate Container will be available at Booth #3285 to discuss and explore Greencoat® applications, benefits, and solutions to meet the needs of growers/packers and retailers.

By working Hand in Hand across the supply chain, Interstate Container makes the transition to Greencoat®, recyclable, coated, and wax-free boxes simple. Offering free trials alongside current packaging, Interstate Container provides growers and packers a chance to effectively test and compare Greencoat®’s strength and performance. These wax-free corrugated boxes are a durable, water resistant, less costly, and 100% recyclable option that meet customer needs.  Why use unrecyclable wax boxes, or dry boxes that don’t perform?  Greencoat® is the box that gives the farmer and retailer the best of both worlds, and saves both money.

Reasons for Growers to Transition to Greencoat

In addition to meeting customer needs for eco-friendly packaging, Greencoat® presents other key advantages for growers and packers.

Stronger & More Durable

Greencoat® corrugated boxes are a true hybrid offering for the industry as they are coated, strong, and also 100% recyclable.   Interstate Container is the only company that can offer a coated, recyclable option that can endure rigors of packing, cooling, and long distance refrigerated trucking to mirror wax corrugated boxes.

Improved Bottom Line

Greencoat® boxes cost less than traditional wax cascaded boxes, offering farmers savings combined with a product that works.  Farmers also don’t have the burden of the administration, damage back charges, and supply concerns that accompany reusable plastic crates (RPCs).

Food Safety

Hygiene is critical for packaging that comes in contact with food products, including fresh produce. A study conducted by researchers from the University of California Davis and the University of Guelph demonstrated that reusable plastic crates (RPC) frequently remain contaminated even when reaching produce packers. [2, 3] Greencoat® eliminates the food safety concerns of packing in unhygienic RPCs.

 Why Greencoat® is Ideal for Retailers

Produce Freshness & Quality

Without strong packaging and the right shipping conditions, fresh produce will reach retailers bruised and wilted. Greencoat® boxes provide the needed strength and water-resistance to ship vegetables in the right temperatures and conditions and maintain freshness and quality.

Revenue Generation

Grocers, foodservice distributors, supermarkets and restaurant chains no longer need to pay $50-70 / ton to landfill wax boxes. Greencoat enables retailers to generate new revenue of $70-100 / ton from recycling the boxes.  This is an enormous benefit to the end user that wax cascaded boxes and RPC’s cannot offer.

Lower Carbon Footprint

Fibre Box Association (FBA) certified, Greencoat® wax-free boxes are 100% recyclable and repulpable. 1,527 million BTUs can be saved by recycling 100 tons of Greencoat boxes, in addition to decreasing greenhouse gas emissions by 312 tons of MTCO2E and 85 tons of MTCE.

About Interstate Container

Interstate Container combines local presence with global experience as a division of Interstate Resources, Inc., employing over 1500 people in the US, and a member of the multinational INDEVCO Group. The company’s reach spans the Eastern and Southern US with 12 manufacturing plants and 7 warehouses located in the New England, Mid-Atlantic, East and South regions.


Contact Info

Jeff Cormier, National Sales & Marketing Manager
Interstate Container
128 Crews Drive
Columbia, SC 2921

Bookmark and Share

Monday, October 3, 2016

Interstate Container to Showcase Greencoat® Double Wall Cabbage Boxes at PMA Fresh Summit 2016

Interstate Resources News homepage: http://news.interstateresources.com

Greencoat®’s new double-wall, coated, wax-free cabbage boxes for growers and packers offer farmers a strong, and cost effective solution to their packaging needs. Find Interstate Container in Booth #3285 at the Orange County Convention Center in Orlando, FL from October 15-16.

October 4, 2016, Columbia, South Carolina – After a successful Spring Interstate Container will display their strong, coated, Greencoat® double-wall cabbage boxes at Booth #3285 during the 2016 PMA Fresh Summit Convention & Expo in Orlando, Florida. Interstate Container is the only manufacturer that can offer this hybrid, coated and recyclable, box offering farmers a unique solution.

Working Hand in Hand with cabbage growers and packers, Interstate Container designed the new 50lb double-wall box to meet the packing and shipping requirements specifically for cabbage.

Greencoat® boxes are strong, water repellent, less expensive than wax, and a 100% recyclable replacement for boxes that commonly ship fresh produce. In addition to double wall cabbage boxes in 10lb, 25lb, and 50lb sizes, Interstate Container produces ½ bushel, ¾ bushel, 1 1/9 bushel, green bean, and many other produce packing options.

Increased Strength & Endurance

Packing and distributing cabbage requires additional strength. Greencoat® double-wall boxes provide 15% increased top to bottom compression strength and higher resistance to bulge.

Enhanced Shipping Performance

Farm-friendly, Greencoat® wax-free boxes protect vegetables from the field or packing shed to foodservice distributors, retailers, and restaurants. Greencoat’s strength and coating give the boxes the power to withstand wet cooler conditions and the strain of long-distance refrigerated trucking.

Reduced Packaging Costs

The packaging costs of Greencoat® boxes are less than wax cascaded boxes. Farmers see a tremendous financial benefit as Greencoat® boxes are less expensive to purchase than traditional wax cascaded boxes.  In addition, the end user can now recycle the box eliminating the need to pay up to $50-70/ton in pickup and landfill costs, while instead generating a steady revenue stream of $70-100/ton when recycling the boxes.

Furthermore, Greencoat® boxes eliminate the administration, damage chargebacks, food safety concerns, and supply issues associated with reusable plastic crates (RPCs).

Improved Grower / Retailer Brand Image

Foodservice distributors, retailers, restaurant chains, cities, and municipalities are increasingly pressuring growers to transition to sustainable packaging. Greencoat® wax-free boxes are 100% certified recyclable and repulpable by the Fibre Box Association (FBA). Recycling 100 tons of Greencoat boxes saves 1,527 million BTUs and reduces greenhouse gas emissions by 312 tons of MTCO2E and 85 tons of MTCE.

“Did you know that every truckload (770 boxes) shipped of cabbage, in wax boxes, has over one ton of material that has to go to the landfill? By transitioning to Greencoat® wax-free boxes, our customers and customers’ customers save money while drastically reducing their carbon footprint.” – Jeff Cormier, Interstate Container National Sales & Marketing Manager explains.

About Interstate Container

Interstate Container combines local presence with global experience as a division of Interstate Resources, Inc., employing over 1500 people in the US, and a member of the multinational INDEVCO Group. The company’s reach spans the Eastern and Southern US with 12 manufacturing plants and 7 warehouses located in the Eastern, Southern, Mid-Atlantic, and Midwestern US.

Contact Info

Jeff Cormier, National Sales & Marketing Manager
Interstate Container
128 Crews Drive
Columbia, SC 2921

Bookmark and Share

Thursday, August 18, 2016

Evergreen Community Power Energy-Saving Efforts Highlighted in Renewable Energy Magazine

Interstate Resources News homepage: http://news.interstateresources.com

Renewable Energy from Waste Magazine discusses Evergreen Community Power’s efforts to help sister company in Reading, Pennsylvania reduce energy use and carbon footprint in the July/August 2016 issue.

Sourced from: http://magazine.rewmag.com/article/july-2016/energy-saving-paper-making.aspx 

Energy-Saving Paper Making

By Hilary Crisan 

The Evergreen Community Power plant is helping a Reading, Pennsylvania paper mill lower its carbon footprint.

Making paper takes up an expansive amount of steam and power. While most paper mills use separate heat and power—an on-site boiler for steam and power from the grid or from a power plant—Interstate Resources Inc., Arlington, Virginia, decided to take an alternative route toward combined heat and power (CHP) for its paper mill located in Reading, Pennsylvania. It built Evergreen Community Power LLC (ECP) to provide fuel and heat for its 100 percent recycled corrugated medium paper mill, United Corrstack (UCI).

Chady Zablit has been general manager of the power facility since it became operational in 2010. He began his career with Interstate Resources and in 1995 and managed the design and construction of ECP in 2006.

“Interstate’s mission spins around sustainability,” he says. “Its core beliefs are that industries can and should care for the environment. Simply put, Evergreen Community Power is one attempt for U.S. manufacturing companies to be less reliant on foreign oil, reduce our carbon footprint and have a diversified national energy source.”


UCI has the ability to produce 200,000 tons of corrugated medium each year. Each ton of paper requires about 6 million British thermal units (mmBtu) of energy.

ECP combusts two primary types of fuel in its boilers: alternative fuel (AF) and clean fuel (CF). AF is the result of a negative picking process where contaminants in the feedstock that increase ash, chlorine and sulfur are removed. The feedstock is shredded and screened before being delivered to ECP. AF is composed of 85 percent wood with the remainder being paper, some plastic and inerts, such as sand and gravel.

CF is the result of a positive picking process where clean and untreated wood is picked, shredded and finely screened out before being delivered to ECP. The plant also receives tire-derived fuel, shredded rail road ties, utility poles, paper mill rejects and sludge in limited quantities.

Since it opened, ECP has combusted more than 1.4 million tons of these fuels. Zablit says when the plant began operations, it had one local feedstock supplier that had all the permits to process the materials but no experience to produce it to the quality required. Over the years ECP geographically broadened its fuel supply mix with feedstock coming to the plant from several different states within a 200-mile radius, including Maryland, Pennsylvania, New Jersey, New York and Connecticut.

“ECP constantly conducts search activities to identify potential feedstock suppliers through information available from the states and permits issued to processors and transfer stations,” Zablit says. Another way the plant discovers feedstock suppliers is through word of mouth among haulers, suppliers and contractors, he adds.

Once a new source is identified and deemed qualified, ECP builds a contractual relationship with the partner.

Since the feedstock is already brought to ECP as a processed material ready to be used as boiler fuel, the company coordinates with a supplier if it doesn’t have the proper equipment to process the feedstock, such as permit changes, adding a shredder or sorting line or introducing a new type of permitted feedstock, explains Zablit.


Location: Reading, Pennsylvania
Project cost: $175 million
Year opened: 2010
System type: circulated fluidized bed boiler
Fuel created: combined heat and power (CHP)
Purpose: Steam and power for United Corrstack’s papermaking process
Feedstock used: Wood waste, C&D debris, paper and some types of plastics
Carbon equivalent saved per year: 100,000 metric tons
Waste diverted from landfill: More than 1.4 million tons

As the plant progressed, feedstock quality from suppliers started to improve as well. Contaminants such as ash, chlorine and sulfur dropped sharply within ECP’s requirements, which was a result of “a combined effort of ECP’s team and our suppliers, who we value as stakeholders in our business,” says Zablit.

The feedstock’s quality also depends on the weather and several different markets. In the winter, obtaining feedstock is difficult because of the snow and freezing temperatures, and the spring causes a wood shortage due to mulch production.

The health of the housing market has its impact on the generation of feedstock materials from construction and demolition (C&D) debris, and industrial power plants using the same type of feedstock can cause unwanted competition.


The plant uses a circulated fluidized bed boiler to heat up the waste used as feedstock. This particular type of boiler, Zablit says, exceeds 99 percent combustion efficiency and is primarily used to fire solid feedstocks such as wood and coal. The temperature of the furnace is between 1,500 and 1,600 degrees Fahrenheit. 

The ECP boiler is rated at 300,000 pounds per hour of steam flow generation with 1,500 pounds per square inch gage pressure and a temperature of 840 degrees Fahrenheit.

The steam created from the boiler is fed to a 33-megawatt rated turbine equipped with three extractions at different pressure levels. These different pressure levels were implemented to support the steam demand of the plant and the paper mill, according to Zablit.

A water-cooled condenser is located at the exhaust of the turbine to cool down the balance of the steam exiting the turbine which becomes water and is fed back into the boiler to complete the steam-water cycle. The cold water is supplied from a cooling tower, which minimizes water needed from outside sources, Zablit says.

The turbine then drives an electric generator that provides electricity to the plant, the mill and to a grid belonging to PJM Interconnection LLC, a Valley Forge, Pennsylvania-based regional transmission organization (RTO) that, according to its website, coordinates movement of wholesale electricity in the District of Columbia and 13 states, including Pennsylvania.

About 70 percent of what is produced at ECP is used for the plant and the mill, Zablit says. The rest is sold to the PJM grid for use in the surrounding area.

Zablit says ECP is currently evaluating the feasibility of adding a grinding operation to the plant, which would allow the company to source clean but oversized wood materials for feedstock.


While ECP is saving about 100,000 metric tons of carbon dioxide equivalent per year, competition is tough.

“Without Interstate Resource’s commitment to the mission and the raison d’ĂȘtre of ECP, I am afraid the plant would have been curtailed a long time ago,” Zablit says. “ECP is in a competitive market where others enjoy a much lower cost to operate and compete.” 

ECP has been working to get the ash generated from the combustion process to become integrated into beneficial use with certain applications, but a lack of interest and regulatory barriers add to the challenges.

“It’s very challenging to operate ECP profitably with the lack of incentives to support this renewable form of generating energy,” Zablit says. “Sales to the PJM grid comes with significant losses, and natural gas, which is the other alternative to generate energy for the paper mill, is also cheap.”

ECP has been running on less than 75 percent of its capacity due to the lack of cost-effective feedstock and a decrease in grid pricing.

“I believe that the public notion of ECP should be positive after converting so many million tons of what would have ended in landfills into a useful form of energy while meeting one of the most stringent air emission permits that regulators produced,” Zablit says. “Such a notion is needed to help establish some incentives and help ECP stay in business.”

The author is assistant editor of Renewable Energy from Waste and can be reached at hcrisan@gie.net.

Evergreen Community Power and United Corrstack are member companies of Interstate Resources, Inc. and INDEVCO.

Bookmark and Share