Rethinking the Core of Tissue Production: CPV at TAPPICon 2025

Earlier this year, the CPV team had the pleasure of joining industry leaders at TAPPICon 2025, one of the pulp, paper, and converting sector’s most influential events. We were thrilled to meet so many of you at the Solution Center Stage, where our own Jack Proudley presented “Reducing Environmental Impact in Tissue Production: The Sustainable Innovation of Polymer Cores (UltraCORE™)” .

The presentation sparked meaningful discussions on how something as ordinary as a parent reel core can play an extraordinary role in a mill’s sustainability performance. It also reaffirmed a shared belief: progress toward decarbonisation doesn’t always require sweeping change, sometimes, it starts with rethinking the smallest components.

For those who couldn’t attend, here’s why this topic and UltraCORE™ generated so much attention.

The Hidden Cost of Traditional Fibre Cores

In tissue production, the parent reel core is fundamental, but its environmental footprint often goes unnoticed. Traditional fibre cores have a limited lifespan, typically lasting fewer than eight rotations before being discarded. Each replacement adds up more manufacturing, more transport, and more waste.

CPV’s lifecycle analysis highlighted the cumulative impact of these short-lived cores. A standard 17-inch fibre core carries a significant CO₂ footprint, and when multiplied across thousands of rolls each year, the environmental toll becomes substantial. For mills focused on efficiency and sustainability, it’s an impact too large to ignore.

A Sustainable Alternative: Built to Last 150+ Rotations

That’s where UltraCORE™ comes in. Engineered as a reusable polymer core system, it represents a shift from disposable to durable. Instead of a component that’s replaced every few runs, UltraCORE™ is designed to withstand 150 or more production cycles maintaining strength, precision, and stability under the high speeds and tensions of modern converting lines.

While any material has an initial carbon cost, UltraCORE™ quickly turns that into an advantage through repeat use. With every rotation, its CO₂ emissions per cycle drop sharply, delivering up to 60% lower total carbon impact compared with fibre alternatives over its lifespan.

It’s a simple change with measurable results: fewer cores manufactured, less transport required, and far less waste entering the system.

Beyond Green: Smarter for Business

At TAPPICon, CPV also explored how UltraCORE™ aligns sustainability with operational and financial priorities. The benefits extend well beyond environmental responsibility:

• Sustainable cost savings: One UltraCORE™ can replace hundreds of single-use fibre cores, reducing purchasing and storage costs.
• Lower CO₂ footprint: Dramatically fewer cores produced and transported means a smaller carbon impact.
• 100% recyclable: At end of life, each UltraCORE™ can be fully recycled, supporting a true circular economy.
• Consistent performance: Engineered for stability, UltraCORE™ maintains precise geometry through every cycle, minimising downtime and ensuring reel integrity.

 By delivering both reliability and sustainability, UltraCORE™ shows that the two can coexist — and reinforce one another.

Why CPV Brought UltraCORE™ to TAPPICon

TAPPICon has long been a hub for new thinking in pulp, paper, and converting. For CPV, it was the perfect venue to start a conversation about quick wins for sustainability practical solutions that can be implemented without costly process changes.

The response was clear: the industry is ready for innovation that delivers immediate, measurable impact. The questions, insights, and enthusiasm from attendees confirmed that sustainability and performance are no longer competing priorities, they’re two sides of the same goal.

Looking Forward

CPV’s role at TAPPICon 2025 wasn’t just to present a product, it was to challenge convention. By rethinking something as fundamental as a reel core, we’re helping mills reduce emissions, improve efficiency, and future-proof operations against tightening environmental targets.

UltraCORE™ represents that vision in action: durable, recyclable, and engineered to perform for 150+ rotations redefining what sustainable production looks like from the inside out.

Explore UltraCORE™

Ready to cut waste and carbon from your production cycle? Contact our team to learn how CPV can help you meet your sustainability goals without compromising performance.