The Former Fusion Paperboard Plant (Part 3)






Welcome back to our journey through Fusion Paperboard. In this third and final part of our series, we head south of the cardboard plant to explore its wastewater treatment facility.


Fusion Paperboard was a leading independent producer of high-performance coated recycled boxboard (CRB), folding cartons, and packaging for major food and consumer product brands across North America. The Connecticut-based paper mill took pride in its sustainable practices, producing 100% recycled, food-grade paperboard. It even earned certification under the Recycled Paperboard Alliance’s (RPA-100%) Recycled Fiber Certification Program.


Each year, Fusion Paperboard recycled more than 160,000 short tons of brown fiber material. That’s a significant commitment to reducing waste and promoting a circular economy. But the company’s dedication to sustainability didn’t stop there. The wastewater treatment plant played a key role in managing the environmental impact of its operations.


In the next section, we’ll take a closer look at how Fusion Paperboard used innovative processes to treat and manage its wastewater, ensuring cleaner water returned to the environment. Stay with us for this final leg of our exploration.































J and I moved casually through the thick, green foliage, the dense underbrush brushing against our legs as we made our way forward. The path was quiet, save for the occasional rustle of leaves and distant birdsong. Before us stood a vine-covered bridge — the final obstacle leading to the remains of the old wastewater treatment plant.


Crossing it carefully, we stepped closer to the first outline of the abandoned facility. Time had claimed its space here. The pools that once held treated water were now lined with green algae, the stagnant water untouched for years. Since the plant’s closure in 2014, nature has crept back in, leaving behind a still, eerie beauty.


It was hard not to wonder what it would have been like if the plant were still operational. Witnessing the process of treating wastewater from recycled paperboard production would have brought the space to life — a tangible example of how industry and sustainability had once worked hand in hand. Instead, all that remained were the remnants of a long-shuttered plant.



















A wastewater treatment plant is an essential part of any paperboard mill, ensuring that the water used during manufacturing is cleaned before being released back into the environment or reused in the factory. At Fusion Paperboard, this process was crucial for managing the large amounts of wastewater produced from recycling materials and making paperboard products.


During production, the water became contaminated with wood fibers, chemicals from bleaching and pulping, and other industrial waste. If left untreated, this polluted water could harm fish, plants, and even drinking water supplies. To prevent that, the treatment plant used a series of physical, biological, and chemical processes to remove harmful substances and meet strict environmental standards.



The process began with physical treatment, where large debris like wood chips, plastic, and sand was filtered out. Screens and settling tanks helped remove these materials. From there, the water flowed into large clarifiers, where gravity allowed heavier particles like fibers and dirt to sink to the bottom. The collected solids were then scraped away and sent for sludge processing.



















Next came the biological treatment stage. In large aeration tanks, the plant introduced helpful bacteria and microorganisms. These tiny organisms feed on the organic waste in the water, breaking it down into harmless byproducts. This step mimicked how wetlands naturally clean water, significantly reducing pollution levels.



For the final stage, the plant used chemical treatments to polish the water. Chemicals like alum or ferric chloride were often added to make small particles clump together, making them easier to remove. Some mills also used activated carbon, a highly absorbent material that trapped any remaining pollutants. In some cases, ultraviolet (UV) light was applied to kill bacteria and ensure the water was safe.


After passing through these steps, the water was tested to ensure it met environmental regulations. Clean water could then be safely released or reused in the mill’s production process. Meanwhile, the sludge from the clarifiers was processed—often dried and either burned for energy, composted, or disposed of in landfills.


And with that, we conclude our exploration of the former Fusion Paperboard plant. Thanks for joining us on this journey! If you’ve ever visited the site or have memories to share, feel free to drop a comment below — we’d love to hear your thoughts.




















If you missed the earlier parts of this three-part series, be sure to check them out:


The Former Fusion Paperboard Plant (Part 1)


The Former Fusion Paperboard Plant (Part 2)


Thanks for reading, and stay tuned for more stories like this!

Comments

Post a Comment

Popular posts from this blog

Waterbury’s Forgotten Factories: The Story of Bristol Babcock

Image
  For nearly a century, the city was known as the “Brass Capital of the World,” with a thriving industrial and manufacturing sector. But when the American brass industry declined in the 1970s, the city was hit hard by a series of economic challenges. Factories closed, jobs disappeared, and in their wake, large areas of land were left contaminated and abandoned. These brownfield sites, once bustling hubs of production, became symbols of the city’s struggle to adapt to a changing economy. By 2019, the city had made significant progress in cleaning up these sites, having remediated over 178 acres of land. Still, 140 acres of brownfields remained, with efforts underway to return them to productive use, offering hope for a new chapter of growth and development. One notable site is the former Bristol Babcock Facility, which operated from 1889 to 1989. The 6.6-acre property, with four buildings dating from 1895 to 1954, straddles the border between Waterbury and Naugatuck. The Bristol Bab...
Read more

Inside the Old Remington Munitions Factory

Image
Over the years, I have had the opportunity to visit the Remington Munitions Factory three times, each visit a unique experience. The first time, I ventured there alone, driven by curiosity to explore what remained of the once-bustling industrial complex. Back then, the neighborhood was far from welcoming, and my solo exploration felt risky. However, the allure of the factory’s history and its remnants was too strong to resist. Upon arrival, the decay was evident. The complex was a shadow of its former self, ravaged by time and neglect. Scrap metal scavengers had stripped the buildings of valuable copper, steel, and iron. Every surface was a canvas for graffiti, a mix of juvenile doodles and more elaborate street art left by local kids and adventurous visitors. A fire in 2017 had already claimed part of one building, and the area had a reputation for violence, with frequent assaults and shootings on Barnum Avenue. Despite the deterioration, the factory had a certain haunting beauty, esp...
Read more

Exeter Energy Tire Incinerator Plant

Image
  We pulled up the long, curving driveway and stopped at the gate. A black pickup truck was parked off to the side. Uneasy, we backed down the road, trying to decide whether to go through with the mission. We should have. Later, as I reviewed the drone footage, I saw it — an open doorway in the back. I can only assume it led straight into the tire-burning facility. But at the time, it didn’t show up on my controller’s feed. I wish we’d at least circled, and taken a look at the rear of the plant before giving up and heading to another site. That hesitation cost us. If we hadn’t let a parked truck shake our resolve, we could have been the only explorers on the entire East Coast to document one of the last two tire-to-energy plants in the country — the only one in New England. It wasn’t just a massive industrial site; it was the region’s primary solution for handling end-of-life tires, processing countless loads into energy. But we never went back. By the time we worked up the nerve a...
Read more

Queens Parkway Hospital

Image
The long-abandoned Queens Parkway Hospital in Forest Hills is finally set for demolition, marking the end of a saga that began over 15 years ago. Nestled in a bustling residential neighborhood off the busy Grand Central Parkway, near P.S. 196 elementary school, the hospital served the community for roughly four decades before shutting its doors in 2008. The closure was part of a broader initiative led by the New York State Commission on Healthcare Facilities in the 21st Century, also known as the Berger Commission. The commission identified Parkway as one of several hospitals with an excess of unused beds, prompting the state’s Department of Health to mandate its closure. Despite a series of legal battles by the hospital’s owners to keep it open, the courts ultimately upheld the decision, sealing Parkway's fate. The hospital's troubles were further marred by scandal. Robert Aquino, Parkway’s CEO, and former State Senator Carl Kruger were both imprisoned after investigators reve...
Read more

Albany Central Warehouse Corporation aka The Cube

Image
In the heart of Albany, nestled amidst the echoes of its bustling past, lies an abandoned warehouse, a treasure trove of stories untold until now. This isn't just any derelict structure; it's the cornerstone of my urban exploration journey, the first of many, but forever the one that initiated me into the world of forgotten spaces. Let's call it the ultimate introduction, the genesis of a passion that has since defined my adventures. Our story begins on a crisp, cold morning that promises adventure. I vividly remember the excitement bubbling up as I set off to pick up my companion, referred to here as "A," from Queens. The journey from the familiar streets of our neighborhood to the unknown mysteries of Albany stretched over three hours, a pilgrimage to our very own urban Mecca. We arrived ahead of schedule, anticipation building as we waited in the chilling embrace of dawn, our breaths visible in the air, our spirits undeterred. Our early morning venture led us t...
Read more