Frank Cottrell Sr. and his two sons converted an idle mill along Kayaderosseras Creek into a specialty paper plant nearly a century ago. Four generations later, the same family still steers the operation in Rock City Falls, New York, proving that stewardship of place and people can outlast market swings and industry consolidations.
Our small-team agility and relentless focus on quality have kept the doors open while neighboring mills faded away. However, we have also been focused on green manufacturing from the beginning, which was rare for electrical insulation papers. Please look closer at who we are and why we strive to be good to the environment while producing top-quality products.
Renewable Power on the Creek
Long before “green manufacturing” became a buzz phrase, the mill’s leadership built a micro-hydroelectric dam supplying roughly a quarter of the plant’s electricity every time the creek ran high, shrinking reliance on fossil fuels and stabilizing energy costs. The same waterway that once powered 19th-century bag machines continues to drive modern papermaking with zero emissions.
Upcycling Cotton for Unmatched Electrical Performance
Our signature rag line starts with post-industrial denim, twill, and other cotton scraps. We shred, clean, and refine those fibers into an ultrapure pulp free of chemical additives that could compromise electrical insulation. Pure cotton yields sheets that resist heat, moisture, and mechanical stress better than wood-based papers. The result is a family of high-grade insulation papers trusted in legacy motors, switchgear, and transformers.
We Strive for Innovation That Keeps Pace With Modern Transformers
Utility engineers asked for improved dielectrics to handle higher voltages, so we invested in precision-forming equipment and new drying technology. Today, our wood-pulp grades meet the tight caliper tolerances as our rag papers while maintaining superior dielectric strength. These grades now make up nearly half of the annual shipments—proof that a 1926-era mill can pivot without losing its soul.
The Zero-Waste Culture Is Well and Alive Inside the Mill
“Use it again” is second nature to us at Cottrell Paper. Edge trim is re-pulped into fresh stock, and sludge—free of dyes and resins—heads to local composters. When upgrading a press or winder, we scout idled mills for salvageable machinery and rebuild it in-house. Our commitment to reusing everything we can keeps excellent steel out of scrapyards and our waste volume as low as possible.
Why We Believe Eco-First Means Superior Quality
Sustainability isn’t a marketing line; it improves the products we produce. The cotton rag fiber, for example, delivers exceptional dielectric strength, low sulfur content, and uniform density. And because many of us grew up in this mill, we monitor every role with the kind of attention no remote dashboard can replicate. The payoff is paper that outperforms spec—not just meets it.
Why Greener Manufacturing Matters for the Environment
- Less deforestation. Upcycling cotton rags and even paper waste from other manufacturing processes eases pressure on forests, protecting biodiversity and natural carbon sinks.
- Lower greenhouse gas emissions. Hydropower and energy-efficient dryers curb CO₂ output at every stage of production.
- Cleaner water. Closed-loop systems and on-site treatment keep pulp fines and bleaching residues out of local streams and away from delicate local ecosystems.
- Reduced landfill burden. Re-pulping trim and composting sludge convert would-be waste into new resources that can save costs on overall production processes.
- Healthier air. Fewer fossil-fuel boilers mean less sulfur dioxide and particulate pollution for the surrounding community.
- Climate resilience. Sourcing renewable energy on-site as much as possible shields us—and the planet—from volatile fuel markets and rising temperatures.
We’re Charting the Next 100 Years with Environmental Responsibility in Mind
Demand for lighter composites and higher-voltage equipment is only growing. To stay ahead, we’re exploring expanded on-site renewables, closed-loop water systems, and digital sensors that pinpoint energy hotspots before they inflate a utility bill—or a carbon footprint. Yet our guiding philosophy remains the same: respect the creek, honor the craft, and keep every coworker personally invested in Cottrell’s future.
Whatever your project calls for, Cottrell Paper is ready to help. Visit our website to see how our eco-first mindset and nearly a century of expertise can deliver the performance your application demands.
