Pregis Opens New Illinois Manufacturing Facility, Creating a Paper Converting Centre of Excellence

Pregis® opened a new 477,000-square-foot paper converting centre in Elgin, Illinois, on 19 September 2025. The facility will support over 500 manufacturing jobs and can produce more than 1 billion curbside recyclable paper packaging solutions annually.

The ribbon-cutting event was attended by Pregis employees at this location and the greater Chicago area, as well as representatives from several community and government offices that support this infusion of economic development.

We are excited about driving forward sustainable initiatives and becoming a part of the Elgin community. This expanded operation represents our commitment to operational excellence and environmental stewardship while creating significant employment opportunities.

Ryan Wolcott, President, Mailing Solutions, Pregis

The zero-waste production complex, powered entirely by renewable energy through Renewable Energy Credits, will host multiple production lines for the company’s Protective Paper and Mailing Solutions offering. The facility is expected to divert an estimated 33,000 tons of waste from landfills as brands transition from plastic alternatives.

The Elgin site will serve as the company’s primary Midwest facility for curbside recyclable paper mailer production. This facility joins four other Pregis mailing facilities nationwide in Arlington, Texas; McDonough, Georgia; Bethel, Pennsylvania; and Reno, Nevada.

Investment in this facility enables Pregis to add capacity, improve manufacturing efficiency and streamline innovation development while enhancing its robust e-commerce product line and expanding fibre-based protective packaging options that address customers’ environmental preferences for widely recyclable materials with critical protective attributes for damage-free delivery.