Wisconsin Rapids Facility: A Century of Innovation
Nestled in the heart of the state of Wisconsin, Billerud's Wisconsin Rapids facility boasts a rich tapestry of history, innovation, and community engagement that spans over a century. From its humble beginnings in 1894 as the Consolidated Water Power Co., the facility has evolved into a beacon of technological excellence in the paper-making industry.
Pioneering Innovations
The journey began in 1894 when a group of paper making pioneers set out to harness the potential of the Wisconsin River. The group owned water rights and property along the Wisconsin River in the twin cities of what was then called Grand Rapids and Centralia (which later merged to become Wisconsin Rapids). They embarked on a mission to consolidate their land, small-scale operations, and various waterpower initiatives into a single, strong entity. Collaboratively, they undertook the construction of a dam, intending to capture the river's power for paper mill operations and contribute any leftover electricity to the local community.
Technological Advancements
In 1904, the company achieved a groundbreaking feat by initiating the world's first electrically powered paper machines, setting a precedent for technological advancements. In the early 1900s, the production expanded to include various paper grades, ranging from newsprint and wallpaper to coated papers for magazines and catalogs. The introduction of new paper machines, coating technologies, and the acquisition of additional facilities contributed to the diversification of the product portfolio. This period also represents a significant milestone in the mill’s sustainability journey. In 1930, the mill launched a forestry program to secure a sustainable supply of wood for future use.
Further Diversification and Growth
During the second half of the 1900s, the mill continued to grow and diversify its operations with new, groundbreaking machines and expansions. The converting plant facility for heavier weight coated paper was inaugurated in 1974, the same year as the water quality center and water renewal center were constructed. The No. 64 paper machine started producing paper for magazines and catalogs in 1979. The expansion of the No. 16 paper machine began in 1990. It started up in 1992, producing heavier weight coated printing paper for annual reports, brochures, and other items. The Wisconsin Rapids Mill idled papermaking operations in June of 2020.
The Wisconsin Rapids Mill and Converting Facility were acquired by Billerud in 2022, and the Wisconsin Rapids Mill's assets were sold in 2024. Today, the converting facility converts rolls of paper made at our Michigan mills into folio and digital sheets as well as rolls of cartonboard imported from our European mills. The converting facility encompasses approximately 470,000 square feet and includes six folio and one digital sheeter, one offline carton packing machine, an automated skid wrapping system, two nine-story automated vertical storage facilities with the capacity to store more than 34,000 tons of inventory, and an automated paper storage and transport system.
Sustainability and Community Commitment
With roots tracing back to the late 19th century, the Wisconsin Rapids facility has been a cornerstone of the local community. Today, together with our employees, the Wisconsin Rapids Converting Facility supports a wide range of community organizations and events with a focus on education, sustainability and local health and human service needs. The facility donated $12,000 to the local community in 2023, with strong community participation driven by our employees who generously contribute their time and talent to volunteering both individually and in various company-sponsored efforts to enhance the quality of life in Wisconsin Rapids and the surrounding area.