It's cardboard season; ever wonder where it all comes from?

A machine the size of a football field makes paper that becomes boxes. (Photo by Christopher Payne, The New York Times)

The people of Windsor, Wisconsin, pop. 8,000, rejoiced when the village's newsletter announced it would have a separate bin for cardboard recycling, all the more important when more Christmas gifts are bought online and shipped. But where does all that cardboard come from?

The corrugated-paper industry runs trees through a marathon of steps before a nifty box emerges, writes Matthew Shaer of The New York Times: "Before it was the cardboard on your doorstep, it was coarse brown paper, and before it was paper, it was a river of hot pulp, and before it was a river, it was a tree. Probably a Pinus taeda, or loblolly pine, a slender conifer native to the Southeastern United States." 

Shaer met up with Alex Singleton, a manager for International Paper, which produces a third of U.S. boxes. His mission "is to source enough loblollies to help keep IP’s production lines humming." He told Shaer, “You’re sort of always in a race. You learn to get creative.” Singleton manages a group of foresters who "spend much of their time zipping around the Southeast by pickup, using a proprietary smartphone app to monitor tracts of harvestable woodland," Shaer writes.

In the woodyard, the creation begins: "A crane was removing timber from a log truck and feeding it into the bladed mouth of a cylindrical machine known as a debarking drum. . . . It churned and chewed and spit the denuded trees from its rear end," Shaer writes. "Another masticating machine, this one a steel chipper. In went the debarked trees, out came a spray of loblolly pine. . . . chips from the woodyard were entering what’s known as the kraft process (the German word for 'strength')."

Shaer describes the 'paper machine,' which "stretched across almost the entire mill floor and trembled like a space shuttle just before liftoff. . . . Pulp sluiced in and cascaded onto the 'former,' where it was flattened into a paper-like consistency." There are more steps, and the end product is corrugated: "If you’ve stopped to look at an individual panel of corrugate and noticed its resemblance to a deli sandwich. There’s a top and a bottom, and between them is a bunch of ridged or diagonally reinforced filler called 'fluting.' That fluting is what gives a cardboard box its protective quality; without its flutes, corrugate wouldn’t be corrugate at all — it would just be containerboard."

The corrugated cardboard industry is booming, Shaer reports: "In 2021, Amazon shipped $470 billion of goods globally, in an estimated 7.7 billion packages." Happy unpacking!