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Embracing The Digital Revolution In Paper Mills

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Explore the significant shift from manual processes to cutting-edge technology as paper mills adapt to the digital era.
Delve into this transformative journey, where we examine key innovations and their impact on efficiency and sustainability in the paper industry.

Riding The Tech-Wave Towards Precision and Sustainability

Paper Mills Factory Plant
Paper and pulp mill – Factory, Plant

By embracing the digital transformation that is occurring in paper mills, companies can pivot from outdated manual processes to innovative solutions. Automated systems optimize production, enhance precision, and fortify sustainability practices.
This exciting shift positions the paper industry to be leaders in technological advancement, aligning productivity with environmental responsibility for a more prosperous and eco conscious future.

Crafting A Digital Tomorrow For Paper Mills

When we look into the history of paper production, we see a legacy grounded in craftsmanship. In the past the intricate process of pulping, bleaching, pressing, and drying, demanded deep and detailed craftmanship understanding.

While this artisanal approach was incredible, it led to many challenges. Manual adjustments meant variations in paper consistency which was further complicated by managing machine speeds through potentiometers.

The constant need for vigilance to prevent issues such as tears and jams added to the complications.

Transitioning from tradition to the digital realm allows paper mills to find strategic solutions to these challenges, ushering in a new path toward precision, efficiency, and sustained quality.

Balancing Legacy and Progress in the Future of Paper Production

In today’s competitive landscape, the paper production sector is confronted with a high demand for expediency in addition to precision. As global markets expand, the pressure to deliver quality at unprecedented speed intensifies.

This demand clashes with the challenges of training a new generation of workers in outdated manual systems. Our young workforce is used to digital interfaces which makes adapting to archaic processes time-intensive and likely to lead to additional errors.

Reliance on aging equipment poses the risk of increased downtime and maintenance creating logistical nightmares for parts and sourcing. Digital transformation is crucial for this industry’s future success.

The interesting case study below illustrates how upgrading and updating a paper machine improved speed, flexibility, and safety at this paper production facility.

Case Study: Paper Mill Update

When a seasoned Midwestern paper mill was grappling with the complexities of a 75-year-old machine, Quad Plus stepped in with expertise and problem-solving solutions. Our team conducted an exhaustive analysis that was focused on adapting to contemporary paper demands ranging from construction to crepe.

Our solution involved a comprehensive overhaul, implementing AC coordinated drives, a master controller, and an automated speed regulation system. We improved speed and draw adjustments giving way to sophisticated automation that fostered operational effectiveness.

Enhanced safety measures were integrated through additional I/O, a safety processor, and safety-rated VFDs. The result was a modernized, streamlined mill, poised to sustain excellence in the dynamic landscape of paper production.

To view the entire case study, click the following link: https://www.quadplus.com/case study/paper-mill-upgrade

Navigating Efficiency, Quality and Safety Through Technological Transformation

The transformation of paper mills redefines production with modern technologies. This evolution creates streamlined operations that enhance proficiency. Automated systems ensure product quality and consistency which increases customer trust.

Operational costs are significantly decreased through less downtime and easier maintenance. Safety is prioritized making exposure to hazards minimal to workers.

Embracing digital transformation is the only way to stay competitive in the contemporary industrial landscape.

Future-Ready Evolution for Paper Mills

In the fast-paced world of paper production, going digital isn’t just an option; it’s the only way to stay relevant. Automation and modernization aren’t just trends; they’re the ticket to a future-proof mill. Upgrading and automating your paper mill is the key to not just surviving but thriving in the ever-evolving industrial landscape.

If you’re ready to take the important steps to protect your mill from future challenges contact Jim at jwoulf@quadplus.com or call (920) 515-4155 for modern and effective solutions.

Independent II ‘Experience Packaging Success’ with Domino

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Independent II, in Louisville, KY USA, is a privately-owned and operated corrugated manufacturer, providing total packaging solutions to their customers. Independent II designs, manufactures, warehouses, and delivers corrugated and packaging that protect their customers’ products in-transit and sells them on shelves.

Finn MacDonald - President of Independent 2
President of Independent II, Finn MacDonald

We caught up with Finn MacDonald, president of Independent II, in a brand-new state-of-the-art facility to learn more about how his business is changing and growing with the Domino X630i digital aqueous inkjet corrugated press. Our visit was captured in this VIDEO: Finn MacDonald on ‘The Domino Digital Advantage’

Experience Packaging Success

Finn begins, “Our motto is ‘Experience Packaging Success’. That’s what we’ve brought to our market for close to 60 years now, and the constants are quality, service, and consistency in relationship…all included in the cost of the box. But there’s been some incredible changes. Independent has moved into a brand-new facility. We are now 340,000 square feet under one roof, and really what we’re changing is from a brown box manufacturer to a brand box and a digital box performer. Our vision was relatively simple… diversify from brown box, but do it in a way that would deliver consistent value and quality to our customers. And it was something that was achievable for us to manage every day.”

Everyday digital

“Everyday digital is really the philosophy that drove my vision for getting digital to our company, and into our market. When Domino came out with the X630i single pass aqueous-based digital press, we said ‘that’s it.’ For us, it’s really as simple as sell it, rip it, and print it… it’s that easy. You’ve got a ton of potential, a ton of capacity, and great innovation to make use of. This is the type of press that we can install in the middle of our converting facility. You don’t need a clean room. You don’t need a lot of special air filtration. You don’t need a lot of special concrete build up floor placement. You’ve got arguably the most compact press on the market, so it’s going to get a whole lot done in a very small footprint. So as far as single pass aqueous-based, there aren’t any players who have a machine like this press available.”

“What it brings to our customers is the ability to think about color. Think about variation. Think about changing your message to your need. And that is really something that we think allows everyday digital to be something that our production team can manage on a Domino press. We have two operators who have zero longtime experience in corrugated. What they do have is hustle. They don’t like the frustration of managing work, but they like to show up and get a lot done.”

The Domino Difference

“Working with Domino made that jump really easy. You’re not jumping alone, you’re with a partner. They have a slogan that says there’s a ‘Domino difference’, and I’ll tell you that it’s absolutely true. It is a relationship that is honest. It’s built on being humble. And there’s a lot of trust involved. So, when you think about the investment in digital, I would say don’t think about an incremental jump. I would say have a bold vision, take a big step, trust Domino to help get you forward faster… with more color, and more pop, and more fun than any other option you got out there.”
To learn more about the Domino X630i corrugated press, please visit: Domino X630i

Domino is a leading manufacturer and distributor of digital printing and product identification solutions. Celebrating its 45th year in business, Domino is a global organization with world headquarters in the UK, and North America headquarters in Gurnee, IL. Domino has 25 subsidiaries, representation in over 120 countries, and over 3,000 employees worldwide. For more information on Domino digital printing, please visit dominodigitalprinting.com

What’s New With Zeta

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On the Shop Floor

Collaborative Robots

collaborative robots

Our shop floor has been a revolving door of collaborative robots getting integrated as Hermes Mobile Cobot Solutions.

Conveyors

conveyors

Our latest conveyor projects included a CDLR conveyor used for transferring a steel pallet.

Zeta’s Commercial on FOX11

This month we started broadcasting a commercial on FOX11 in the mornings and evenings.

Paper, Pulp and Converting Industry Summary

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Wisconsin Paper & Pulp Industry Update

In the 1970’s, the Paper and Pulp Industries employed close to 30,000 people in Wisconsin. Back then, paper mills had integrated pulp mills, plus certain in-house converting capabilities. Wisconsin had 20 paper and pulp facilities close down.

Marty Oaks

Now, in late 2023, the state has 8,194 employed in these industries. There are just a couple of paper companies with pulp production, plus some converting capabilities. Currently, most of the pulp comes from other states, Canada, and foreign companies. A considerable number of paper mills outsource their converting needs, or they simply provide mill rolls to converting companies.

Converters: 1. Cut rolls at the paper mill’s request; 2. For their own sales offerings; 3. Or conduct value-added steps for contracted customers.

According to a 2018 industry report, Wisconsin’s Pulp, Paper, and Converting Industries employed 30,262 workers, with sales of $18 billion. The report states that Wisconsin has twenty-four paper companies with thirty-four locations. Our GBIG research identified twenty-two paper companies with twenty-nine locations (See Attachment B). In addition, we have witnessed a number of paper mills being closed.

Based upon the Wisconsin industry report, paper and pulp mills generated $6.5 billion in output per year. Based upon a report from Stastista, the total annual revenue of paper and pulp mills in the USA is $38.2 billion in 2023. The 2018 report stated: The paper and pulp industry in Wisconsin employed 8,459 with 5,581 in Brown County.

Current Paper & Pulp: The Green Bay Innovation Group (GBIG) is conducting a comprehensive report making direct contact with the paper and pulp industries. We have determined that 8,194 people are employed in paper and pulp manufacturing companies in Wisconsin.

Paper Converting: Based upon the same report, paper converters employ approximately 19,265 people in Wisconsin. After reviewing the report, our analysis shows a substantial number of companies are not really converters for inclusion among paper products listings as direct converting “partners.” The report was based upon NAICS statistics which included everyone involved in converting. A case in point: label companies were included because they have converting capabilities.

If we simply identify true paper converters supporting the paper industry who take jumbo rolls, slit, rewind, provide sheeted products, and carry out other related services, we find fewer than 20. Part of the difference in estimates is due to varying definitions.

Our research has identified a much larger number of converters that provide value-added materials: 1. As outsourced by paper companies; or 2. As value-added steps by converters for their customers; or 3. They convert final finished products.

In addition, Wisconsin has a large number of converters who work with flexible films, labels, nonwovens, and non-paper substrates that are not naturally part of paper and pulp statistics.

We have defined converting as receiving raw materials on mill rolls and transforming them into value-added or finished products.

A Deeper Dive into Paper Stats

  • The average number of employees in a paper mill is 207.4 employees based upon IBISWORLD statistics.
  • A report from IBISWORLD cites the number of paper mills in the US as (129) as updated in late September 2023.
  • Based upon the IBIS World report, paper mill employees in the US is 43,556 in 2023. A report from Stastista states that the paper industry in the United States employed 48,364 people as of 2022. With this comparison, the number in the US is between 43,556 and 48,364.

The Wisconsin Industry 2018 report shows that the paper industry employment includes the Forestry Industry. Forestry employment is a separate category from paper. Additionally, we are witnessing the forest, logging and upstream industries supporting paper and pulp declining over 30-40%, and we expect the trend to continue with a major impact on employment. Unfortunately, there are very few pulp mills in Wisconsin producing virgin pulp and it is having a significant impact on the logging and forestry industries. There is still a need for virgin fiber to produce a wide variety of products. We have seen many companies using recycled pulp.

Past reporting in the Wisconsin Paper Industry cites the paper, pulp and converting industries having 30,262 workers.

COMING NEXT: For another perspective, the Green Bay Innovation team will be breaking out converting as a separate sector to show each facet of the overall paper and converting Industries.

Paper Industry Is Changing

Wisconsin is no longer a major player supplying printing papers, with no production of coated groundwood papers, coated free sheets, and the state is a minor player in uncoated free sheets. Printers, converters, and packagers are buying most of their papers outside of Wisconsin and turning to Europe, Asia, Indonesia, and South America.

Downturn

Verso shut down the Wisconsin Rapids Paper and Pulp Mill, and current owner Billerud has no apparent intention of ever reopening to produce printing paper for the USA markets. At the present time, the majority of Wisconsin paper and pulp mills are foreign owned. Therefore, buyers are being forced to purchase paper from foreign paper mills, and foreign paper companies are determining the future of the Wisconsin paper and pulp industry.

  • We speculate that the state of Wisconsin paper, pulp, printing, packaging, converting and all the other supporting industries will have to consider the supply chain future. They will need to determine whether Wisconsin values in-state production of paper for the strong downstream industries.
  • Industry players will have to assess their related futures. With current geopolitical events, Wisconsin companies are at serious risk, being able to secure paper to support their businesses. Wisconsin has all the resources to support paper and pulp manufacturing. If Covid did not demonstrate a lesson about Supply Chain stresses, current geopolitical issues are now a big stressor for our paper and related industries. This industry is critical to the State of Wisconsin, with all the manufacturing dependent on it for regional and national security and prosperity.
View Marty’s full overview

Look for the Upcoming Summary on Converting

Paper Industry in Wisconsin and What Happened to It

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Appvion logo

We see the CCP and State supported Paper Companies pouring in Billions of Dollars buying up US and Canadian Paper Mills. Chinese and Indonesian companies are investing into mega-mills betting that China can control the Paper and Pulp Industry worldwide with low-cost paper. Simply the State of Wisconsin needs to re-focus its support and investment in the paper industry. If not, we will see China buying up our Converting, Printing, Packaging and Manufacturing Companies too! Wisconsin needs to be the leader in re-shoring our Paper Industry back to the USA! We have ALL the ASSETS to do it!
Wisconsin has seen well over 20 Paper and Pulp Mills shut down!

  • Appvion – Appleton – No longer producing paper.
  • Appleton Coated – Appleton – Out of business.
  • Badger Paper Mills – Bankrupted and reorganized BPM, Inc.
  • Billerud – Verso mill in Wisconsin Rapids shutdown
  • Clearwater Paper Company – Neenah – Closed
  • Flambeau Paper Company – Park Falls – Closed
  • George Whiting Paper Company – Menasha – Closed
  • Georgia-Pacific – Day Street in Green Bay Closed
  • Georgia-Pacific – Oshkosh – Shutdown
  • Gilbert Paper Company – Closed
  • Glatfelter Mill – Neenah – Closed
  • Kimberly-Clark – Neenah – Moved Headquarters to Texas
  • Neenah Paper Company – Moved headquarters to Georgia.
  • Nekoosa Edwards Paper – Nekoosa operating as Paper Excellence
  • New Page – Kimberly files for bankruptcy
  • Niagara Paper Company – shutdown
  • Port Edwards Paper Company – Port Edwards – Shutdown
  • River side Paper Company – Appleton – Shutdown
  • Ward Paper Mill – International Paper – Merrill – Shutdown
  • Wausau Paper Company – Wausau – Shutdown
  • Whiting Paper – Menasha – Shutdown

December 13th, 2023 Newsletter

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GBIG logo

Read the December 13th, 2023 Green Bay Innovation Group Newsletter here.

Read newsletter

GBIG NEWS | 2 Christmas Stories and Links on the Internet 12/13/2023

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GBIG News

Get links to the latest news, events, stories, and interviews from our 5P news sponsors. Our goal is to remind the decision-makers in Wisconsin of the importance of our industry both historically, and more importantly, into the future.

Read the latest 2 Christmas Stories and Links on the Internet below.

GBIG News Banner

Christmas

Christmas with Our Children hosted by the Children’s Museum and sponsored by the Green Bay Innovation Group and Alliance Construction

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Family wearing believe statement shirts

Hundreds Jingle All The Way at The Children’s Museum of Green Bay’s Breakfast with Santa

A rainy morning didn’t slow Santa and his reindeer from flying in from the North Pole to celebrate the season with kids and families at the annual Children’s Museum of Green Bay Breakfast with Santa

The fifth annual Breakfast with Santa took place at Mackinaws Grill and Spirts Saturday, December 9, 2023. The event featured standard breakfast fare as well as live reindeer, cookie decorating, letters to Santa, toy testing stations, hot chocolate, bird feeder building, face Painting and more!

Heather R. Heil is one of the organizers of the event and she says the idea for this unique celebration was started 5 years ago when the pandemic helped to refocus on how we serve our families; we hosted a drive-up breakfast and Santa hosted a drive-up breakfast at Mackinaws.

“There’s a lot of different Christmas events around town, and it’s hard to get to all of them. With the help of our partners, we try to bring all the fun to one spot!” says Heil.

2023 partners included: Mackinaws Grill and Spirts, Fox Communities Credit Union, Festival Foods, Green Bay Innovation Group, Alliance Construction and Design.

About The Children’s Museum of Green Bay (CMGB)

The Children’s Museum of Green Bay is a 501c3 that focuses on play based learning. The CMGB has emerged as a community leader that provides an inclusive, unique interactive environment where play inspires a passion for lifelong learning.

2 women posing in the camera
Santa Clause with 2 little girls

Lighting Up the Holidays at GRB – Unveiling the 2023 Holiday Trees

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FOR IMMEDIATE RELEASE December 5, 2023
(Green Bay, Wis.) The holidays are here and Green Bay Austin Straubel International Airport (GRB) is excited to unveil three uniquely designed trees to travelers and community members for the first annual Tree Lighting Ceremony on Wednesday, December 6 at 4:30 p.m.

2 little girls holding a snowflake ornament

Over the past two weeks, Green Bay West High School, 4th graders from King Elementary School and the Handmade Papermakers of Green Bay, Students of Aldo Leopold Community School (ALCS) have crafted exquisite holiday tree themes which will be displayed for holiday travelers.

“Watching the students and faculty of each of these schools come together to bring their designs to life has been truly amazing,” said Marty Piette, A.A.E., Airport Director. “Their stories and visions will bring smiles to our travelers, and they’ll learn something along the way.”

Green Bay West High School’s design includes fused glass snowflakes, uniquely crafted by students and staff to represent the individuality of each person that makes up our community. The snowflakes will adorn a 20-foot artificial evergreen stationed in the pre-security Grand Lobby of the airport.

4th Graders from King Elementary School brought the stories, history and culture of the Onedia Nation to their 10-foot artificial evergreen. Beadwork, language, custom ornaments and more will tell the story of what it means to Oneida Nation members. This tree will be seen by travelers going through Concourse A, post-security. Photos of the tree will be available for viewing during the ceremony.

Handmade Papermakers of Green Bay, Students of Aldo Leopold Community School (ALCS) used the history of our area’s papermaking to create handcrafted snowflakes for their 10-foot artificial evergreen. Their tree will be positioned post-security at Concourse B. Photos of this tree will also be made available during the ceremony for viewing.

“Sharing our area’s culture, history and creativity to all those that travel this season is a real treat,” said Troy Streckenbach, Brown County Executive. “It’s an honor to have these students take the initiative to come together to learn and create such beautiful pieces.”

The Tree Lighting Ceremony will take place in the Grand Lobby of the airport and will include a viewing and lighting of the Green Bay West High School’s “Crystalized” tree. For security reasons, Concourse trees will be unavailable to non-ticketed guests. Photos will be available for viewing of these trees at the ceremony.

  • little man creating a sponge
  • woman decorating the Christmas tree
  • 5 people posing in front of a decorated Christmas tree indoors

About Green Bay Austin Straubel International Airport

Green Bay Austin Straubel International Airport (GRB) is the third largest airport in the state, serving Northeast Wisconsin and portions of Michigan’s Upper Peninsula. Business and leisure flights are offered by five major airlines, American, Delta, Frontier, Sun Country and United Airlines, and two fixed base operators (FBOs), JetAir Group and Executive Air. As the Gateway to Lambeau Field, GRB is a Green Bay Packers Partner and the home airport of the Packers.

Additionally, GRB is one of only two commercial airports in Wisconsin designated as a Landing Rights Airport by the U.S. Customs and Border Protection for international flight arrivals.

Find GRB online:
www.flygrb.com | Facebook | Twitter | YouTube

Media Contacts:
Marty Piette, A.A.E. – Airport Director Katie Flanigan
Green Bay Austin Straubel International Airport Leonard & Finco Public Relations, Inc.
920-498-4800 920-965-7750 ext. 152
Marty.Piette@flygrb.com kflanigan@LFpublicrelations.com

The Green Bay Innovation Group Partners with Apricity to raise $15,000 in matched donations.

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Double the Impact of your year-end gift to apricity

YOU can make an impact with a year-end gift to Apricity! Donations to be DOUBLED thanks to matching funds from Green Bay Innovation Group and an anonymous family. Give ONLINE at apricityservices.com and click the red banner at top of page.

Donations support the employment and recovery program at Apricity Contract Packaging (ACP). ACP partners with companies to provide contract packaging and assembly services for manufacturers who need additional resources, capabilities, or workforce. Apricity provides those impacted by substance use disorders a full spectrum of care including treatment, employment and support services in a safe, progressive recovery community.

Krissa’s Second Chances Lead To Purpose In Life

“Before coming to Apricity’s Casa Clare residential treatment I was in inpatient treatment two times, prison treatment and outpatient treatments. Nothing seemed to stick, and I’ve had countless negative experiences with counselors.

Despite all this, I decided to give Apricity a try. I’m glad I did! The counselors were amazing. I could relate to them. They didn’t come off as thinking they were better than the patients they treated, like it was other places I tried getting help. I loved that some of the counselors had first-hand experience in addiction. They talk with and treat all clients like we are human beings, and the entire Apricity program gave me hope.

Krissa Brasure

I am really grateful for the opportunity to have had treatment, then move through and work at Apricity’s Contract Packaging (ACP) job-training program. It is through ACP that I built my self-confidence and redeveloped a work ethic. I stayed working there for one year while living in Apricity’s Sober Living program, where I still live now and recently became the house manager for the new Ola sober living women’s house. It is through these recovery supportive programs that I not only received treatment but strengthened my recovery. It is here that I have been supported in reconnecting with family and repairing relationships I thought were lost. It is here that I learned coping and communication skills that really helps with life in the long run.

Apricity has taught me and showed me that recovery means a second chance at a life worth living. I am grateful for these many second chances to get where I’m today, because I feel like I have found a purpose in life. Apricity encouraged me to pursue my dreams, including someday going back to school, which I did! This fall I enrolled at Fox Valley Technical College to become a substance use counselor so that I can pay it forward. While going to school, I am now working part-time as a House Manager at Apricity’s Mooring House and Casa Clare residential treatment facilities, gaining hand-on experience working with clients and counselors. My hope in pursuit of this dream and my future was that I could come back to Apricity, so I could give back what I got. And, I am!”
-Krissa Brasure

Krissa Brasure is a former Apricity Residential Treatment client and Contract Packaging program participant. She is currently part of Apricity’s Sober Living program and is a house manager for the program. Krissa has been in recovery since August 2, 2022.

Apricity is a proud sponsor of GBIG.

Green Bay Innovation Group

Bringing Green Bay Companies Together. Green Bay Innovation Group is committed to building an authentic networking experience where innovation can thrive.

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