Smurfit Kappa Corrugated Packaging Manufacturing Facility

Mold, Wales

A new extension makes Smurfit Kappa’s Mold facility the largest box factory in the UK.

A world leader in packaging production, Smurfit Kappa is a FTSE100 company with over 50 locations in the UK alone. As a supplier of shelf ready packaging for a range of sectors, they are facing increasing demand for sustainable packaging.

The new extension to their Mold facility provides a 35% increase in size to meet that demand, whilst investment in state-of-the-art equipment aims to reduce CO2 per tonne emissions by 15% at the plant.






Smurfit Kappa


CWC were appointed to provide enhanced performance design to Stage 3, forming a robust suite of tender documents for the complete project including CAT B M&E design for the new manufacturing and materials handling machinery. CWC also provided ongoing client side technical and quality assurance support throughout the tender period, construction, machine installation and handover.

This highly technical and specialised project included negotiation and procurement of a new 4.5MVA electricity supply, designing a new private high voltage infrastructure throughout the facility including three private packaged substations, and designing the specialist M&E services to the machinery in addition to the general facility M&E services.

The specialist services to machinery include power distribution, comms / telemetry connections, process water, steam and starch plant and distribution, compressed air and effluent pipelines.

The base build and services install was completed in December 2022, with machinery installation completed and put into service early 2023. The existing facility was in operation throughout the project with careful phasing design resulting in only one period of scheduled downtime. 

Key stats

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