Producing newspapers between 1983 and 2021, the Shotton Mill Limited site is to be transformed by Eren Holding into its main paper manufacturing centre in the UK. The project represents one of the most significant investments in manufacturing in the UK and, once operational, will be one of the most advanced of its kind in Europe. 

Arup was appointed as lead designer to provide multidisciplinary engineering services from the early stages of the project, including development of a site masterplan and co-ordination of site services, through to construction and final completion. We delivered the project in close collaboration with Eren Holding, working from offices in both the UK and Turkey. 

Shotton Mill will produce 750,000 tonnes of recycled containerboard annually, hosting the UK’s largest 100% recycled containerboard paper machine. It will shift the UK from net importer to net exporter, reuse a quarter of currently exported fibre and use waste‑heat for efficient energy. The project is expected to secure and create 400 jobs, strengthening the local economy.

Delivering as part of a collaborative team   

Arup worked closely with the Eren Holding to agree the methodology for the phased building works, including demolition, refurbishment and new build elements. Demolition of the former newsprint mill ran concurrently with the necessary surveys and advanced works. We collaborated with the site operational team to ensure safe delivery and embed a strong safety culture. 

As lead designer, we co-ordinated all parties to work as a single integrated team, working with the planning consultant, contractors and stakeholders. During construction, our co-located staff supported delivery in line with the design intent, ensuring sustainability runs through every element. The new facility features a new building fabric, significantly improving UK U-Value targets, as well as high-performance systems and lighting.  

Another ambition was to minimise freshwater usage while maintaining process water quality. We designed a bespoke sustainable water management system by expanding the private drainage network, repurposing existing ponds and introducing a series of balancing ponds and treatment works. This enables water reuse and reduces overall consumption. 

A large white building.

Aerial view of the revitalised Shotton industrial facility, showcasing Arup’s integrated approach to modern industrial design and engineering.

We are delighted to have the expertise and experience of Arup leading the design of this development. Arup’s support of the design and implementation in the UK and Turkey was a key factor in choosing them as our partner. This is a very exciting time in the mill and we look forward to working with Arup to deliver a world-class manufacturing facility in North Wales.

Dan Johnson

General Manager, Shotton Mill

Leveraging digital and data to drive efficiency   

Digital and data tools also played a significant role in the development of the project. We created a digital archive of site records, capturing the existing utility routes to give the client a comprehensive understanding of its infrastructure.  

Additionally, we developed a multidisciplinary digital design model which allowed us to detect clashes and coordinate design development, which minimised risks during the construction phase.  

Shotton Mill represents a seismic shift for the UK manufacturing industry, helping to transform recycling levels while demonstrating leading sustainability principles. 

Partners & collaborators

AHR Architects Limited